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WX210

WX240
HYDRAULIC EXCAVATOR

Service manual
Print No. 9-91270 English

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.


Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING - Cautions directed to avoid improper repair interventions involving potential consequences
for the safety of the personnel performing the repairs.
DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organisation of the Manufacturer, observing strictly the instructions explained using, whenever necessary,
the recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own, for
the damages that may result.
Neither the Factory nor any Organisations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused
by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandised by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandised by the Factory, when failures are caused by the use of parts and/or components not approved by the
Factory.

AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the
farm, at home or on the road, are caused by the failure of some individuals to follow simple and fundamental safety rules and precautions. For this reason
MOST ACCIDENTS CAN BE PREVENTED by
recognising the real cause and doing something
about it before the accident occurs.
Regardless of the care used in the design and construction of any type of equipment, there are many
conditions that cannot be completely safeguarded
against without interfering in the reasonable accessibility and efficient operation.
A careful operator is the best insurance against an
accident. The complete observance of one simple
rule would prevent many serious accidents.
The rule is simple: never attempt to clean, lubricate or
maintain a machine while it is in motion.

WARNING
Prior to engaging in any maintenance, adjustment
or repair operation on machines having hydraulically, mechanically, and/or cable controlled
equipment (such as shovels, loaders, dozers, excavators etc.) be certain the equipment is lowered
to the ground.
If it is necessary to have the equipment partially
or fully raised to gain access to certain items, be
sure the equipment is suitably supported by means other than the devices used for controlling
the equipment.

SUMMARY
SAFETY INSTRUCTIONS

SECT. 0

TECHNICAL DATA AND SPECIAL TOOLS

SECT. 1

MACHINE STRUCTURE

SECT. 2

ELECTRICAL SYSTEM

SECT. 3

ELECTRONICS

SECT. 4

HYDRAULICS

SECT. 5

TROUBLESHOOTING AND REPAIR

SECT. 6

REPAIR INSTRUCTIONS

SECT. 7

Service manual
Section 0 Safety Instructions
WX210 - WX240

9-91270

0-2

SAFETY INSTRUCTIONS

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

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Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0-3

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SAFETY INSTRUCTIONS

WX210 - WX240

Table of contents

PREFACE ....................................................................................................... 6
To the reader ................................................................................................................................... 6
Handling ......................................................................................................................................................... 6
Repair............................................................................................................................................................. 6
Further information material........................................................................................................................... 6

Warnings and symbols................................................................................................................... 7


Risks resulting from failure to observe the safety instructions ................................................. 7

SAFETY INSTRUCTIONS .............................................................................. 8


Personal safety instructions.......................................................................................................... 8
Observe the safety instructions...................................................................................................................... 8
Protection from noise ..................................................................................................................................... 8
Preparing for emergencies............................................................................................................................. 8
Wearing protective clothing............................................................................................................................ 9

Safety instructions before starting work .................................................................................... 10


Checking the machine ................................................................................................................................. 10
Keeping the working area clean................................................................................................................... 10
Using grab handles and steps ..................................................................................................................... 11
Adjusting the operators seat ....................................................................................................................... 11
Applying the safety belt................................................................................................................................ 12

Working from the operators seat only ....................................................................................... 12


Never take passengers on the machine ..................................................................................... 12
Safety instructions for machine operation ................................................................................. 13
Before setting off .......................................................................................................................................... 13
Note the position of the working equipment................................................................................................. 13

Taking care during operation ...................................................................................................... 13


Taking care when trenching......................................................................................................................... 14

Distance from overhead power lines .......................................................................................... 14


Accident Prevention when reversing and slewing ....................................................................................... 15
Rules for driving on the road........................................................................................................................ 16
Recovering and towing the machine............................................................................................................ 16
Travelling uphill and downhill ....................................................................................................................... 17
Preventing the machine from overturning.................................................................................................... 18
Inspecting the deployment location.............................................................................................................. 18
Parking the machine safely.......................................................................................................................... 19
Preventing accidents when the machine is moving ..................................................................................... 19
Confirming the direction of machine travel .................................................................................................. 19
Avoid caving out high banks ........................................................................................................................ 20
Protection from rockfall and landslides ........................................................................................................ 20
Caving prevention ........................................................................................................................................ 21
Never move the bucket above persons ....................................................................................................... 21

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0-5

Safety instructions, maintenance/servicing............................................................................... 22


Safety during transport................................................................................................................................. 22
Safety during servicing operations............................................................................................................... 23
Warning instructions for servicing work ....................................................................................................... 24
Correct machine support.............................................................................................................................. 24
Working at greater heights........................................................................................................................... 25
Keeping clear of moving parts ..................................................................................................................... 25
Prestressed units ......................................................................................................................................... 26
Never remove lead seals ............................................................................................................................. 26
Safety instructions for accumulators ............................................................................................................ 26
Dismantling components.............................................................................................................................. 27
After repair work........................................................................................................................................... 27
Correct waste disposal................................................................................................................................. 27
Welding operations ...................................................................................................................................... 28
Starting the engine with starter batteries ..................................................................................................... 29
Prevention of acid-induced burns ................................................................................................................ 29
Prevention of scalding.................................................................................................................................. 30
Safe handling of fluids.................................................................................................................................. 30
Fire prevention ............................................................................................................................................. 31
Evacuation in case of fire............................................................................................................................. 32
Risks from exhaust gases............................................................................................................................ 32
Risks from fluids in pressure systems.......................................................................................................... 33
Preventing heat build-up close to pressure systems ................................................................................... 34
Preventing heat build-up in lines carrying combustible fluids ...................................................................... 34
Removing paint before welding.................................................................................................................... 35
Risks from breaking-away components ....................................................................................................... 36
Use appropriate tools ................................................................................................................................... 36

Warning and instruction signs .................................................................................................... 38


Organizational measures ............................................................................................................. 42
Selection and qualification of personnel; basic responsibilities ................................................................... 43
Safety instructions governing specific operational phases .......................................................................... 43
Warning of special dangers ......................................................................................................................... 45

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0-6

SAFETY INSTRUCTIONS

WX210 - WX240

PREFACE

40000000-en

To the reader
The Technical Manual (TM) has been written for
the repair specialist. It provides important information on carrying out repair work expertly.

information on maintenance standards, removal


and installation procedures, and dismantling and
assembly procedures.
The required information can easily be found by
referring to the table of contents.

Please go carefully through the Technical Manual as well as the Owners Manual for the hydraulic excavator before starting any repair work.
Use the Technical Manual as well as the
Owners Manual and spare-parts list as a reference book and source of information even if you
are familiar with hydraulic excavator technology.

For reasons of clarity, some of the illustrations are


presented in simplified form. Differences from the
actual version at the hydraulic excavator are
therefore possible if this adds to the clarity of the
information.

Using the Technical Manual, the experienced


construction machine mechanic can carry out any
necessary repairs expertly.

Carry out any necessary repair work as soon as


possible. This reduces repair costs and increases
the availability of your hydraulic excavator.

Handling

When doing any work on the hydraulic excavator,


always observe the instructions given in the
Technical Manual and in the Owners Manual.

The Technical Manual is divided into eight sections and covers the originally delivered version of
the machine. Any additions or modifications undertaken at a later date are not described in this
manual.

Repair

Extensive works not described in the Technical


Manual will gladly be executed for you by the O&K
after-sales service.

- Introduction

Always use original spare parts only.

- Safety Instructions

Further information material

- Technical Data and Special Tools


- Description of Functioning

Please consult the following documents in addition to this Manual:

- Performance Testing

- Owners Manual

- Troubleshooting

- Spare-parts catalogue

- Repair Instructions
- Annex
The Safety Instructions section describes the
recommended procedures to be observed in order
to prevent any risk of accidents to the operator
and to the personnel responsible for the works
and for machine servicing measures.
The Description of Functioning section provides
technical information on operating the main devices and systems.
The Technical Data and Special Tools section
lists service data, conversion tables and special
tools and servicing materials required.
The Performance Testing section gives the information required for carrying out performance
testing.
The Troubleshooting section contains information on detecting faults in the machine.
The Repair Instructions section gives the technical information needed to carry out servicing and
repair work on the machine, describes the equipment needed for servicing works, and provides
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Warnings and symbols


The following signs are used in the Technical
Manual to designate exceptionally important information:

0-7

Risks resulting from failure to observe


the safety instructions

This hydraulic excavator has been


built in accordance with state-ofthe-art standards and recognized
safety regulations.

Precautionary rules and measures


designed to protect the operator
and other persons from lifethreatening hazards or injury and to
prevent extensive damage to property.

Nevertheless, its use may constitute


a risk if it continues to be operated
despite damage being suspected or
having occurred, or if it is inexpertly
repaired.
There is then a risk of

Information
and
precautionary
measures designed to prevent damage to the machine and other property.

life-threatening injury

irreparable damage to the machine


and other assets.

The hydraulic excavator must be


stopped immediately if suspected
damage or damage that has occurred affects the safety of the operator, other persons at the excavator deployment site, or other assets.
All components are carefully coordinated. Trouble-free operation and
a long service life are assured only
if original spare parts are used.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0-8

SAFETY INSTRUCTIONS

WX210 - WX240

SAFETY INSTRUCTIONS
Personal safety instructions

40000004-en

Protection from noise

Observe the safety instructions


-

Read carefully through all safety


instructions attached to the machine and observe them; read all
safety instructions in this manual
in addition.

Safety instruction stickers/plates


must be affixed, maintained and
replaced when necessary.

If a safety instruction sticker/plate


or this manual is damaged or missing, obtain a replacement from
your dealer. The procedure is the
same as when ordering spare parts
(it is essential to quote the machine type and the serial number).

Familiarize yourself with the correct, safety-oriented procedure for


operating the machine and its control elements.

Allow only trained, qualified and


authorized persons to operate the
machine.

Keep the machine in good working


order.

Unauthorized modifications to the


machine may affect its efficiency
and/or safety and reduce its service life.

The instructions given in this


Safety Instructions section are designed to show the fundamental
safety procedures for the machine.
However, they cannot cover all
hazardous situations with which
you may be confronted. If in doubt,
consult your immediate superior
before operating the machine or
carrying out servicing work.

Sustained effects of noise may lead


to impaired hearing or deafness.
Wear appropriate ear protectors
such as earplugs or muffs for protection from disturbing or intolerable
noise.

Preparing for emergencies


Be prepared for the event of a fire
breaking out or an accident occurring.
Keep the first-aid box and the fire
extinguisher readily accessible at all
times.
Read the instructions for operating
the fire extinguisher and learn how
to use it properly.
Stipulate emergency procedures for
the event of fire or accidents.
Keep the emergency numbers of
doctors, emergency services, hospitals and the fire service in the immediate vicinity of the phone.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Wearing protective clothing


Wear close-fitting clothing and protective equipment suited to the work.
You need:
-

a safety helmet

safety footwear

goggles or face guard

protective gloves

ear protectors

reflective clothing

waterproof clothing

respirator or filtering mask.

Ensure that you wear the right


equipment and clothing for the job.
-

Never take risks.

Never wear loosely fitting clothing,


jewellery or other objects that
might get caught on operating levers or other machine components.

Safe operation demands the operators complete attention. Never wear


headphones to listen to the radio or
to music while operating the machine.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0-9

0 - 10

SAFETY INSTRUCTIONS

WX210 - WX240

Safety instructions before starting work


Checking the machine

40000008-en

Keeping the working area clean

Before starting up the machine each


day or before each shift, give the
outside of the machine a careful
visual inspection to prevent damage
and injury.

Fig. 1

Check the machine for superficial


damage.

Check before starting work that all


covers and caps are closed and
locked.

Clean the working area before


starting work.
-

Remove any objects that might


endanger the mechanics or persons in the working area.

Keep your cab clean and cleared;


loose items may disturb the machine operation.

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Using grab handles and steps

Adjusting the operators seat

Falls are one of the main causes of


injury.
-

Fig. 3

A seat that is poorly adjusted with


respect to the operator or the working conditions may result in premature operator fatigue and thus in
faulty operation.

Always face the machine when


entering or leaving it, and use
only the aids provided, e.g. steps
and handrails.
Never use operating elements as
grab handles.

Never jump down from the machine.

Never climb up onto or down from


a moving machine.

Watch for slippery platforms,


steps and handles when leaving
the machine.

0 - 11

The seat must be adjusted with


any change of machine operator.

The operator must be able to depress the pedals completely and


move the control levers effortlessly with his back resting
against the backrest.

If that is not possible, move the


seat forward or back and check the
setting again.
Consult the relevant section in the
Owners Manual.

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 12

SAFETY INSTRUCTIONS

Applying the safety belt

Working from the operators seat only

If the machine overturns, the operator may be injured and/or thrown


out of the cab. He may be severely
injured or even crushed to death by
the overturning machine.
-

Starting up the engine incorrectly


may cause the machine to make
unexpected movements that might
lead to severe, even fatal, injury.

Before operating the machine,


check the belt fabric, the closure
and the fastening components
carefully. If one of the parts is
damaged or worn, replace the
safety belt or the components before starting up the machine.
Always remain seated and keep
the safety belt fastened while operating the machine. This will help
minimize the risk of injury in the
event of an accident.

Always start up the engine from


the operators seat only.

Never start the engine by shortcircuiting the starter.

After starting up the engine, check


that all driving levers, driving
pedals and control levers are in
neutral position.

Never take passengers on the machine

The safety belt must be replaced


after any serious accident even if it
appears to be undamaged.

Fig. 5

WX210 - WX240

Passengers on the machine may


suffer injury e.g. from foreign bodies or through being thrown off.
-

Only the operator is allowed onto


the machine. Never take passengers.

Passengers also obstruct the operators view so that the machine


is no longer safely operated.

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 13

Safety instructions for machine operation


Before setting off

40000022-en

Taking care during operation

Remove any soil, mud, snow, ice,


grease and oil from your working
footwear before operating the machine. You might otherwise slip
from steps and pedals and thus
initiate inadvertent movements.

If the front equipment or another


part of the machine collides with a
higher obstacle, e.g. a bridge, both
the machine and the other object
are damaged, and persons may be
injured.

Adjust the drivers seat and the mirror before setting off.

Take care to prevent the boom or


stick from colliding with higher
obstacles.

Close the front window and the cab


door.
If the machine is equipped with a
restraining belt for the operator,
fasten the belt.
Before setting off, sound the horn to
warn any persons in the immediate
vicinity.
Never allow other persons to travel
with you on the machine.

Note the position of the working equipment


Never drive with the working
equipment extended, as that may
impair the stability of the machine.
Bring the working equipment as
close as possible to the machine.

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 14

SAFETY INSTRUCTIONS

Taking care when trenching

Distance from overhead power lines

The inadvertent severing of underground cables or gas pipes may


cause an explosion and / or fire.
This may result in severe, potentially fatal injury.
-

Before doing any trenching work,


check the course of cables, gas
pipes and water pipes.

Observe the statutory minimum


distance from cables, gas pipes
and water pipes. Never look into
the end of an inadvertently severed fibre-optics cable, as that
may severely injure the eyes.

WX210 - WX240

Severe, potentially fatal injury may


result from the machine or the front
equipment not being kept well clear
of overhead power lines.

Contact the local authorities and /


or supply enterprises (electricity,
gas, water, sewage, telecommunications etc.) to obtain information
on underground supply lines.

If work is being done close to an


overhead power line, no part of
the machine or the load must
come within a distance of 3 m
plus twice the length of the overhead power line insulator from the
power line.

Check out and observe the relevant local regulations.

Wet ground increases the range in


which a person may get an electric shock.

Keep all persons or colleagues


clear of the location.

After contacting live wires


-

Do not leave the machine.

Drive the machine out of the hazard zone. Warn others against approaching and touching the machine.

Have the live wire de-energized.

Do not leave the machine until the


contacted / damaged line has been
de-energized with absolute certainty.

Fig. 8

Fig. 9

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 15

Accident Prevention when reversing and slewing


Any person in the immediate vicinity
of the machine may be hit or run
over when the machine is being
reversed or the superstructure is
being slewed. This may result in
severe, potentially fatal injury.
To prevent accidents during reversing and slewing:
-

Enlist the assistance of a marshaller if your view is restricted.

Always look in all directions before


reversing or slewing. Make sure
there is no one in the immediate
vicinity.

Keep the acoustic reversing alarm


(if present) in a good operating
state.

Always be prepared for the possibility of persons entering the hazard zone. Use the horn or another
signal to warn any persons in the
immediate vicinity.

Enlist a marshaller for reversing if


your view is restricted. Always ensure that the marshaller is within
sight.

The machine must not be moved


until agreement has been reached
with the marshaller on correct interpretation of the signals.

Familiarize yourself with the meaning of all markings, signs and designations used in the operation
and come to an agreement on them
with the marshaller.

Keep windows, mirrors and headlamps clean and in good order.

Dust, heavy rain, fog, etc. may


reduce visibility. If this is the case,
reduce your speed and switch on
appropriate lighting.

Read the Owners Manual carefully.

Fig. 10

Fig. 11

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 16

SAFETY INSTRUCTIONS

Rules for driving on the road


The machine must not be driven on
the public highway unless the conditions of the General Operating
Permit are observed or, in the
event of deviations from the General Operating Permit, a vehiclespecific operating permit has
been granted. These permits must
be present in the cab during such
travel.
-

Always have a warning triangle,


warning lamp and first-aid kit on
board.

Bring the working equipment into a


position in which the maximum
machine dimensions are not exceeded.

Switch the bucket/grab switchover


valve to "Grab" position. The
bucket cylinder is then hydraulically blocked.

Mount clearance lamp on stick and


connect to a socket.

Raise levelling blade completely


and attach a reflector.

Raise claws (option) completely


and block mechanically.

Switch off floodlamps.

Lock superstructure..

WX210 - WX240

Recovering and towing the machine


Tow the machine with a tow-rod or
towing rope only.
The tow-rod or rope must be free
from damage. They must be dimensioned in such a way that the calculated breaking load is equal to three
times the tractive power of the towing machine.
The towing vehicle must have adequate tractive power.
Drive
slowly,
smoothly.

carefully

and

All persons must keep clear of the


tow-rod or rope.

Tow only if the brakes and the


steering of the machine are functioning properly and if the machine
cannot be otherwise transported.

Tow defective machines only as far


as necessary to recover the machine from hazardous areas.

After the recovery, the machine


must be secured against inadvertent movements and unauthorized
starting.

Have the machine repaired before


transporting it over greater distances, or load it onto a transport
vehicle.

The machine is not suitable for


towing trailers or other vehicles
over longer distances; this would
result in damage to axles and
gearboxes. The tow coupling is
designed solely for towing or recovering vehicles from hazardous
areas or for lashing purposes on
transport vehicles.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 17

Travelling uphill and downhill


Before starting up the machine, read
through the Owners Manual carefully.
-

Before driving the machine, put it


into neutral position (see Owners
Manual).

Never drive down slopes with a


gradient of more than 30. Take an
alternative route with lower gradients.

Keep the bucket 20 - 30 cm above


the ground on the uphill side while
travelling uphill or downhill.

If the machine starts to slip or to


lose its stability, lower the bucket
immediately.

Driving across slopes may cause


the machine to slip or overturn.

Steering manoeuvres on slopes


may cause the machine to overturn.

Never coast downhill. This may


result in a loss of control over the
vehicle and in severe damage to
property as well as fatal injury.

Always change to first gear before


the downhill / uphill slope. This increases the brake action of the
travel motor, preventing inadmissibly high travel speeds.

When working on a slope, the fuel


tank must be topped up as soon as
the fuel indicator lights up.

Fig. 12

Fig. 13

Fig. 14

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 18

SAFETY INSTRUCTIONS

Preventing the machine from overturning

Inspecting the deployment location

Working on slopes always entails a


risk of the machine overturning.
This may result in severe, potentially fatal injury.

Working at the edge of excavations


or on the verge of a road entails a
risk of the machine overturning.
This may result in severe, potentially fatal injury.

To prevent overturning:
-

Exercise special care when working on a slope.

Prepare the working area of the


machine by levelling it.

Keep the bucket close to the


ground and to the machine.

Reduce the working speed of the


machine to prevent overturning or
slipping.

Avoid changing direction when driving on a slope.


-

Always try to avoid crossing a


slope with a gradient of more than
5 degrees.
When slewing a load, reduce the
slewing speed to meet safety requirements.

Special care must be taken when


working on frozen ground.
-

Fig. 15

WX210 - WX240

Before starting work, inspect the


site and the ground conditions to
prevent any risk of the machine
overturning and of the ground, a
stockpile or a wall giving way.

If necessary, the ground, excavation site edges and verges must be


reinforced. Keep sufficient clearance with the machine from the
edges of the excavation site and
the verges.

When working on a slope or on the


verge of a road, enlist the services
of a marshaller if necessary.

If the ground has a poor loadbearing potential, reinforce it before starting work.

Special attention is needed when


working on frozen ground. If the
ambient temperature rises, the
ground becomes soft and slippery.

A rise in temperature softens the


soil, impairing the stability of the
machine during travel.

Fig. 16

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Parking the machine safely

0 - 19

Preventing accidents when the machine is


moving

To prevent accidents:
-

Park on a flat, horizontal surface.

Turn the brake switch to braking


position.

Set the working equipment down


on the ground.

Lower the levelling blade and/or


the outrigger claws onto the
ground.

Engage the superstructure lock.

Run the engine unloaded at minimum speed for ca. 5 minutes.

Turn the ignition key to OFF position to switch off the engine. Then
withdraw the key.

Move the steering safety lever to


block the machine.

Lock the windows, the sliding roof


and the cab door.

Lock all covers and flaps.

Severe or fatal accidents may result


from an attempt to enter or leave a
moving machine.
-

Before leaving the operators seat,


select a flat, horizontal area for
parking if possible.

Park the machine safely.

Block both wheels and set the


working equipment down on the
ground.

Park at a reasonable distance


from other vehicles.

Fig. 18

Confirming the direction of machine travel


Inadvertent activation of the operating pedal may result in severe
damage or fatal accidents.
Check the machine position. Read
the corresponding section in the
Owners Manual.

Fig. 17

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 20

SAFETY INSTRUCTIONS

Avoid caving out high banks

Protection from rockfall and landslides

The edges may cave in or there


may be a landslide. This can result
in severe, potentially fatal injury.

Fig. 19

WX210 - WX240

Before working at locations with a


risk of rockfall, make sure your
machine has a cab with a Falling
Object Protective Structure (FOPS).

Fig. 20

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Caving prevention

Never move the bucket above persons

To reverse away from the edge of


an excavation in the event of the
ground giving way, the tracks must
always be positioned with the rear
travel motors at right angles to the
edge of the excavation.

The bucket must never be lifted,


moved or slewed above persons or
a truck cab.
Material falling from the bucket or a
collision with the bucket may result
in injury and in damage to the machine.

Do not panic if the ground starts to


give way and adequate withdrawal
is impossible. In such cases the
machine can often be secured by
lowering the front equipment.

Fig. 21

0 - 21

Fig. 22

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 22

SAFETY INSTRUCTIONS

WX210 - WX240

Safety instructions, maintenance/servicing

40000024-en

Safety during transport


-

At the top end of the ramp, which


adjoins the loading area, there is a
joint. Drive over it with care.

Ensure that local regulations are


observed when the machine is being transported on the public
highway.

When slewing the superstructure,


avoid fast movements as they
might cause the machine to overturn, resulting in potential injury.

An appropriate truck or trailer must


be provided for the transport of the
machine.

Keep the stick retracted and turn


the superstructure slowly to ensure maximum stability.

Secure the machine frame with


chains or cables.

There is a risk of the machine overturning when it is being loaded onto


a truck or trailer and when it is being unloaded.
-

When loading/unloading the machine, the following precautions


must be taken:
-

Find firm, horizontal ground.

Always use a loading platform or


drive-on ramp.

A marshaller must be enlisted to


help with loading/unloading the
machine.

When loading or unloading the


machine, the automatic speed reset must always be switched off to
prevent an unexpected increase in
speed due to inadvertent activation
of an operating lever.

Always set the transmission stage


switch to "slow".
In the "fast" transmission stage, the
travelling speed may be automatically increased.
-

Details are given in the appropriate


sections of the Owners Manual.

Fig. 23

Avoid steering movements when


driving up or down the ramp, as
that is extremely dangerous. If
steering is absolutely essential,
first drive back onto the ground or
the loading area, correct the driving direction, and set off again.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 23

Safety during servicing operations


Disconnect the cable from the
negative pole of the battery before
doing any work on the electrical
system or arc welding on the machine.

To prevent accidents:
-

Before starting work, familiarize


yourself with the servicing procedure.

Keep the working area clean and


dry.

Never perform any lubrication or


servicing work while the machine
is in motion.

Before carrying out servicing work


on the machine:
-

Park the machine safely.

Never leave the machine unsupervised if servicing work has to be


carried out with the engine running.

If the machine has to be raised, the


boom and stick must be positioned
at an angle of 90 - 110. Secure the
machine components that have to
be raised for servicing or repair
work with appropriate supports.

Fig. 24

Work must never be done under a


raised machine that is supported
by the boom.

Certain components have to be


checked at regular intervals and
repaired or replaced if necessary.
Details are given in the corresponding sections of the Owners Manual.
-

Use original spares only.

All components must be kept in a


good state and correctly installed.
Any defect must be repaired immediately.

Fig. 25

Any damage must be rectified immediately. Worn or nonfunctioning components must be


replaced. Remove any lubricating
grease, oil and dirt deposits.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 24

SAFETY INSTRUCTIONS

Warning instructions for servicing work

Correct machine support

Unexpected machine movements


may result in serious injury.
-

Fig. 26

WX210 - WX240

Never carry out work on the machine without first securing it.

Prior to doing any work on the machine, display a notice "Servicing


work in progress" to ensure that
the machine is not used inadvertently.

Always lower the working equipment or the tool onto the ground
before working on the machine.

If you have to work on a raised


machine or raised working equipment, stabilize the machine or
working equipment with a support.

The machine must not be supported with hollow blocks, tyres or


supports that give way when continuously loaded.

Never work under a machine that is


supported with lifting gear only.

Fig. 27

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Working at greater heights

Fig. 28

0 - 25

Keeping clear of moving parts

Always wear a safety harness when


working at greater heights.

Catching in moving parts may result


in severe injury.

Wear an approved safety harness; it


must be equipped with stabilizers
and safety cables.

To prevent accidents, care must be


taken to ensure that hands, feet,
clothing, jewellery and hair cannot
get caught in moving parts when
work is being done close to them.

Fig. 29

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 26

SAFETY INSTRUCTIONS

Prestressed units

WX210 - WX240

Safety instructions for accumulators

Never open defective prestressed


systems but replace the entire system.

Accumulators are installed in the


hydraulic system. They contain nitrogen under high initial pressure.

Open only in exceptional cases,


when the system and the operational sequence are exactly known
and the necessary special tools are
available.

Even when the hydraulic system


has been depressurized, the nitrogen pressure is maintained in the
accumulator.

Never remove lead seals


Never change the rated pressure of
pressure-reducing valves without
the explicit authorization of the
manufacturer.
Never remove lead seals from pressure-reducing valves and accumulators.

The accumulators are completely


safe in operation. If incorrectly handled, however, there is a risk of explosion.
The accumulators installed in this
machine cannot be repaired. Defective accumulators must be replaced.
Never handle accumulators mechanically, never weld or solder
them.
Before dismantling the accumulator,
put on goggles and working gloves,
and depressurize the hydraulic system.
Use original spares only. If in doubt,
contact your local agent or the aftersales service.
Never remove or paint over warning
and information plates, rating plates
or type identification markings. Replace illegible or damaged plates
immediately.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Dismantling components
Never dismantle while the machine
is still at operating temperature.
Oils, greases, brake fluid or coolant
may have a high temperature and
thus result in burning or scalding.
Wait for the machine to cool down.
Depressurize pipelines and hoses,
cylinders, radiator, hydraulic tank,
compressed air reservoir and other
systems or units before starting
work.
Replace defective components in
good time to prevent greater damage.
Clean the defective component
carefully before dismantling it.
Mark dismantled components in the
correct sequence to facilitate installation.
When dismantling the component,
close exposed hose and pipe connections, open boreholes and housings with care to prevent dirt from
penetrating.

0 - 27

After repair work


To prevent corrosion, coat all bright
metal machine components with a
grease film.
On completing the work, reassemble all protective devices, covers,
and sound- and vibration-insulation
material.
Never start up the driving motor
while work is being done on the machine.
Check the repaired components and
all machine functions with a trial run.
Never release the machine for recommissioning until it is fully functioning.

Correct waste disposal


Incorrectly discarded waste is an
environmental hazard. Hazardous
substances used in excavators include lubricants, fuels, coolants,
brake fluids, filters and batteries.
-

Use sealed containers to discard


fluids. Never use containers designed for food or drinks.

Never discard waste onto the


ground, into drains or into water.

Ask your local authorities, collection points or dealer about the correct procedure for recycling or discarding waste.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 28

SAFETY INSTRUCTIONS

WX210 - WX240

Welding operations
Never perform welding operations
unless you are qualified to do so.

Before any welding operations on


the machine:
-

Any work on receptacles that contain or have contained substances

Disconnect the battery, first at the


negative and then at the positive
pole.

that are flammable or encourage


combustion,

Disconnect the positive pole at the


alternator.

that are susceptible to explosion,

that may develop noxious gases,


fumes, vapours or dusts during
welding operations

Protect disconnected terminals


and plugs from short-circuiting
and contamination by covering
them with foil or adhesive strips.

Observe the accident prevention


regulations.

may be performed only under expert


supervision and only by experienced personnel authorized to do
such work.
Detailed information on the proper
execution of welding operations is
given in the corresponding sections
of this manual.
Contact the O&K Service department with any problems or questions arising.

Bring the welding current terminals


as close as possible to the welding
point.
The welding current must not flow
through the slewing ring, pin couplings, link joints or hydraulic cylinders.
Restore all electrical connections
after completion of welding operations.
When connecting the battery, connect first the positive pole terminal
and then the negative pole terminal.

If machine components have to be


dismantled, read and observe the
sections:
-

"Assembly of working equipment safety instructions,

"Inspection and servicing - safety


instructions",

"Repair - safety instructions".

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Starting the engine with starter batteries

Prevention of acid-induced burns

Battery gas may explode, causing


damage and injury.

The sulphuric acid contained in the


battery is toxic. It is so strong that it
may burn the skin, burn holes in
clothing and, if splashed into the
eyes, lead to blinding. Therefore:

If the engine is to be started up with


starter batteries, ensure that all procedures described in the Owners
Manual are observed.
-

0 - 29

The operator must be seated on


the drivers seat to keep the machine under control when the engine starts up. Two persons are
needed to start up the engine with
starter batteries.
Never use batteries that have been
stored for long periods at low temperatures.
Mistakes in implementing the procedure specified for starting up the
engine with starter batteries may
result in a battery explosion or unexpected machine movements.

Top up the batteries on well ventilated premises only.

Wear goggles and rubber gloves.

Take care not to inhale the electrolyte vapours while topping up the
batteries.

Make sure no electrolyte is spilt or


runs over.

Use appropriate starting aids in an


emergency.

If splashed with acid:


-

Rinse the skin with plenty of water.

Neutralize the acid by spreading


sodium bicarbonate or fullers
earth over it.

Rinse out the eyes for 10-15 minutes with water.

Seek medical advice immediately.

Battery gases may explode.


-

Keep sparks, lit matches or open


flames away from the upper side of
batteries.

The battery charge must never be


controlled by applying a metal object to both pole terminals. Use a
voltmeter or an acidity meter.

If acid has been swallowed:

A frozen battery must not be


charged; it may explode. Heat the
battery up to 16 C.

Drink large quantities of water or


milk, milk of magnesia, raw beaten
egg or vegetable oil.

Seek medical advice immediately.

Battery acid is toxic. If the battery


explodes, battery acid may splash
into the eyes with a potential risk of
blinding.
-

You must wear eye protection


when checking battery acidity.

Fig. 30

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 30

SAFETY INSTRUCTIONS

Prevention of scalding

Safe handling of fluids

Hot, spattering fluids:


-

WX210 - WX240

Handle fuel with care: it is highly


flammable. Igniting fuel may result
in an explosion or a fire with the
risk of severe, potentially fatal injury.

After machine operation the engine coolant is hot and under


pressure. Hot water or steam is
contained in the engine, radiator
and heating lines. If escaping hot
water or steam touches the skin, it
may cause severe scalding.
To prevent potential injury
through hot, spattering water:
Never remove the radiator cover
until the engine has cooled down.
To open the cover, turn it slowly
as far as the limit stop. Depressurize the radiator completely before
opening the cover.

When refuelling the machine,


smoking and the use of open
flames or sparks in the immediate
vicinity are prohibited.

Always shut off the engine before


refuelling.

Refuelling must be done in the


open air.

All fuels, most lubricants and some


antifreezes are flammable.

The hydraulic tank is under pressure. Depressurize it completely


before removing the cover.
Hot fluids and surfaces:

Flammable fluids must be stored


where they are protected from fire.

Pressurized containers must not


be opened with force or incinerated.

Never keep oily rags: risk of selfcombustion and fire.

Engine oil, gearbox oil and hydraulic oil also heat up during operation.
The engine, hoses, lines and other
components also heat up.
Give the oil and the components
time to cool down before starting
servicing or inspection work.

Fig. 32

Fig. 31

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 31

Fire prevention
Checking for leakages:
-

Leakages of fuel, hydraulic oil and


lubricants may cause fires.

Check whether clips are missing or


loose, hoses are kinked, lines or
hoses rub against one another, the
oil cooler is damaged or oil cooler
flange screws are loose, allowing
oil to escape.

Missing, loose or damaged clips,


lines, hoses, oil coolers or oil
cooler flange screws must be replaced, tightened or repaired.
High-pressure lines must not be
bent or hammered.

Removal of flammable substances:


-

Spilt fuel or lubricant, waste, lubricating grease, dirt, coal dust deposits and other flammable substances may cause fires.

To prevent fires, the machine must


be checked and cleaned once a
day. Any spillages or deposits of
flammable substances must be
cleared away immediately.

Checking the ignition key function:


-

If the engine is not shut off when


fire breaks out, the fire will spread,
impeding fire-fighting operations.

Before starting daily machine operations, the ignition key must be


checked for correct functioning.

Never install bent or damaged


lines, tubes or hoses.

Checking for short-circuits:


-

Short-circuits may cause fires.

Ensure that all electrical connections are clean and have a firm fit.

Check before each shift or after ca.


ten operating hours whether electric
cables or lines are loose, kinked,
hardened or worn through.

Start up the engine and run it at a


low idling speed.
To confirm that the engine is shut
off, turn ignition key to OFF position.
-

Any irregularities that are detected


must be rectified before the machine is put into operation.

Checking heat shields:

Check before each shift or after ca.


ten operating hours whether terminal caps are missing or damaged.

The absence of heat shields or any


damage to them may result in fire
breaking out.

-Never start up the machine if cables or lines are loose, kinked, etc.

Damaged or missing heat shields


must be repaired or replaced before
the machine is put into operation.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 32

SAFETY INSTRUCTIONS

Evacuation in case of fire

Risks from exhaust gases

If a fire breaks out, evacuate the


machine as follows:
-

WX210 - WX240

Prevent the risk of suffocation. Engine exhaust gases may cause


nausea or even death.

If there is sufficient time, shut off


the engine by turning the ignition
key to OFF position.

If there is sufficient time, use the


fire extinguisher.

If you have to work in a building,


make sure there is adequate ventilation.

Use an exhaust pipe extension to


remove the exhaust gases, or open
doors and windows to let in sufficient fresh air.

Leave the machine.

4100033

Fig. 33

Fig. 34

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 33

Risks from fluids in pressure systems


Pressurized fluids such as fuel or
hydraulic oil may penetrate the skin
or eyes, resulting in severe, potentially fatal injury or blinding.
-

Cut out this risk by depressurizing


the system before disconnecting
hydraulic or other lines.

Tighten all connections before


pressurizing the system.

Using a piece of card, search for


any leakages; be sure to protect
hands and body from fluids under
high pressure. Wear a face guard
or goggles to protect your eyes.

Fig. 35

Seek medical advice immediately


after an accident. Any fluid that has
penetrated the skin must be removed surgically within a few hours
to prevent severe infection (gangrene).

Fig. 36

Fig. 37

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 34

SAFETY INSTRUCTIONS

Preventing heat build-up close to pressure


systems

WX210 - WX240

Preventing heat build-up in lines carrying


combustible fluids

Heat generation close to pressurized fluid lines may result in a


highly flammable spray, putting
you and other persons in the immediate vicinity at risk of serious
scalding.

Never carry out welding or flamecutting work on pipes or lines carrying combustible fluids.

Flush them out with a non-flammable solution before welding or


flame-cutting them.

Never carry out heat-generating


welding or soldering work close to
pressurized fluid lines or other
highly flammable substances, and
never use a flame cutter there.
Pressure lines may be inadvertently cut if the heat goes beyond
the immediate flame area. To provide temporary protection for
hoses or other materials, mount
fire-resistant shields when carrying
out welding or soldering work.

Fig. 38

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 35

Removing paint before welding


Hazardous fumes may develop if
paint is heated by welding, soldering or the use of a flame cutter.
These fumes may affect your health
if inhaled.
-

Avoid inhaling potentially toxic


fumes and dust.

Carry out such work only in the


open air or on well ventilated
premises.

Paints and solvents must be discarded in accordance with local


environmental regulations.

Fig. 39

Remove paint prior to welding or


heating:
-

When rubbing down paint, avoid


inhaling the dust.

Wear an approved respiratory


mask.

When using a solvent or paint


remover, remove the agent with
soap and water before any welding operations. Remove all solvent or paint remover containers
and other inflammable materials
from the working area. Give the
fumes at least 15 minutes to dissipate before any welding or heating.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 36

SAFETY INSTRUCTIONS

Risks from breaking-away components


The tyres are inflated under pressure Bursting tyres and breakingaway rim parts may cause serious
damage or fatal accidents.
-

Tyres must be changed by experts


only.

Always ensure that the tyre pressure is correct. Insufficient tyre


pressure means greater wear on
the tyres and poor machine stability.

Excessively high tyre pressure


means poor handling properties on
terrain and a risk of bursting tyres.

Prior to inflating tyres, check rims


and rim components for damage,
penetrating foreign bodies and a
firm fit.

Never inflate tyres above the recommended pressure.

Leave tyres to cool down before


working on them.

Use only compressed ambient air


to inflate tyres. Never use combustible gases: risk of explosion.

WX210 - WX240

Use appropriate tools


Use only tools suited to the respective work.
Inappropriate tools, components
and procedures may result in hazardous situations.
Use tools whose length is suitable
for the tightening or loosening of
safety elements to prevent injuries
resulting from failure to control a
wrench.
Never use tools complying with US
standards or British standards for
metric connection elements.
Use original spares only (see spareparts catalogue).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 37

0 - 38

SAFETY INSTRUCTIONS

WX210 - WX240

Warning and instruction signs

40000025-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

9. Risk of injury from electric current. Keep the


following distances from live wires:

Observe
the
warning
and
instruction signs attached to the
machine.

up to 1000 V (1 kV) = 1 meter,

Keep the signs clean and legible.

from 1 kV to 110 kV = 3 meters,

Replace the signs immediately if


they are no longer legible.

from 110 kV to 220 kV = 4 meters,


from 220 kV to 380 kV = 5 meters,

New warning and instruction


signs can be obtained from our
spare-parts service. The part no.
for ordering is set out in the
spare-parts list of your machine.

unknown voltage = 5 meters.


10. The steering works only when the engine
is running.
11. Check the oil level in the engine before putting
the machine into operation.

Legend
1. Risk of injury from moving parts of the working equipment. Move the working equipment
only after all persons have left the hazard
zone.
2. This sign indicates that the working equipment
reaches far out over the machine and that
it can be moved without moving the machine.
3. Risk of injury from falling loads or moving
parts of the working equipment. Do not stand
under suspended loads or under the working equipment.
4. The CE mark indicates that this machine has
been built in compliance with the European directives concerning the safety of machines.
LWA indicates the level of noise emissions in
dBA (acc. to standard 2000/14/EC).
5. Lifting gear can be attached here when parts
of the machine are to be removed.
6. This sign
pressure.

0 - 39

specifies

the

prescribed

12. This signs shows all control levers and pedals


and the movements of the working equipment
and the travelling gear initiated with these
elements. Observe also the information set
out in the Operator's Manual.
13. Risk of injury from hot or rotating parts in the
engine compartment. Open the hood of the
engine compartment only after the engine is
stationary.
14. Emergency operation for slewing drive and
parking brake. For detailed information refer
to the Operator's Manual.
15. Risk of injury from falling loads or moving
parts of the working equipment. Do not stand
under suspended loads or under the working
equipment.
16. Type rating plate of the machine.

air

7. This signs states the admissible maximum


speed for travelling on public roads.
8. Do not put the machine into operation unless
you have read and understood the Operator's
Manual.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 40

SAFETY INSTRUCTIONS

WX210 - WX240

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Observe
the
warning
and
instruction signs attached to the
machine.
Keep the signs clean and legible.
Replace the signs immediately if
they are no longer legible.
New warning and instruction
signs can be obtained from our
spare-parts service. The part no.
for ordering is set out in the
spare-parts list of your machine.

0 - 41

Legend
1. Alternator, regulator and electronic modules
may be damaged, if the batteries are disconnected with the engine running. The engine
must therefore be shut off before the batteries
are disconnected and removed.
2. Hydraulic oil reservoir.
3. Hydraulic oil reservoir. Observe the Operator's Manual. The reservoir is filled with a
special hydraulic fluid (option).
4. Fuel tank.
5. Risk of injury from slewing superstructure
or moving machine. Slew the superstructure
and drive the machine only after all persons have left the hazard zone.
6. Fastening means must be attached here
when the machine is to be transported.
7. Control elements for the auxiliary heating
system (option).
8. This sign shows the layout of the machine
points to be regularly greased. The sign states
also the change intervals for consumables
and filters.
A detailed list of all regular servicing activities is contained in the inspection and maintenance schedules (Part 3 of these Operator's
Manual).
Always perform servicing in compliance with
the maintenance schedules.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 42

SAFETY INSTRUCTIONS

WX210 - WX240

Organizational measures
The Owners Manual must always be at hand at
the deployment site of the machine, e.g. in the
container provided.
In addition to the Owners Manual, observe and
instruct the user in all other generally applicable
statutory and other mandatory regulations relevant
to accident prevention and environmental protection.
These compulsory regulations may also deal, for
example, with the handling of hazardous substances, the issuing/wearing of personal protective
equipment, or traffic regulations.
The Owners Manual must be supplemented by
instructions covering the duties involved in supervising and notifying special organizational features,
such as job organization, working sequences or
deployed personnel.
The personnel assigned to work on the machine
must have read the operating instructions and in
particular the Safety Instructions section before
starting work. Reading the instructions after work
has begun is too late. This applies especially to
persons working only occasionally on the machine,
e.g. during setting-up or servicing.
Check at least occasionally whether the work is
being carried out in compliance with the Owners
Manual and with attention being paid to risks and
safety factors.
Long hair must be tied back or otherwise secured,
garments must be close-fitting, and no jewellery
including rings may be worn. Injury may result from
such items being caught up in the machinery or
catching on moving parts.
Use personal protective equipment wherever required by the circumstances or by law

40000059-en

Observe all safety instructions and warnings attached to the machine.


See to it that safety instructions and warnings attached to the machine are always complete and
perfectly legible.
In the event of safety-relevant modifications or
changes in the behaviour of the machine during
operation, stop the machine immediately and report the malfunction to the competent authority/person.
Never make any modifications, additions or conversions which might affect safety without the supplier's approval. This also applies to the installation
and adjustment of safety devices and valves as
well as to welding work on load-bearing elements.
Spare parts must comply with the technical requirements specified by the manufacturer. Spare
parts from original equipment manufacturers can
be relied upon to do so.
Replace hydraulic hoses within stipulated and appropriate intervals, even if no safety-relevant defects have been detected.
Adhere to prescribed intervals or those specified in
the Owners Manual for routine checks and inspections.
For the execution of maintenance work, tools and
workshop equipment equal to the task on hand are
absolutely indispensable.
The personnel must be familiar with the location
and operation of fire extinguishers.
Observe all fire-warning and fire-fighting procedures.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

0 - 43

Selection and qualification of personnel;


basic responsibilities

Safety instructions governing specific operational phases

Any work on / with the machine must be executed


by reliable personnel only. Statutory minimum age
limits must be observed.

Standard operation

Deploy only trained or instructed staff and set out


clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair.
Make sure that only authorized personnel works on
/ with the machine.
Define the machine operator's responsibilities
also with regard to observing traffic regulations giving the operator the authority to refuse instructions by third parties that are contrary to safety.

Avoid any operational mode that might be prejudicial to safety.


Before starting work, familiarize yourself with the
surroundings and circumstances of the site, such
as obstacles in the working and travelling area, the
soil bearing capacity and any barriers separating
the construction site from the public highway.
Take the necessary precautions to ensure that the
machine is used only when in a safe and reliable
state.

Do not allow persons to be trained or instructed or


persons taking part in a general training course to
work on or with the machine without being permanently supervised by an experienced person.

Operate the machine only if all protective and


safety-oriented devices, e.g. removable safety
devices, emergency shut-off equipment, soundproofing elements and extractors, are in place and
fully functional.

Work on the electrical system and equipment of


the machine must be carried out only by a skilled
electrician or by instructed persons under the supervision and guidance of a skilled electrician and
in accordance with electrical engineering rules and
regulations.

Check the machine at least once per working shift


for obvious damage and defects. Report any
changes (incl. changes in the machine's working
behaviour) to the competent organization/person
immediately. If necessary, stop the machine immediately and lock it.

Work on chassis, brake and steering systems must


be performed only by skilled personnel specially
trained for such work.

In the event of malfunctions, stop the machine


immediately and lock it. Have any defects rectified
immediately.

Work on the hydraulic system must be carried out


only by personnel with special knowledge and experience of hydraulic equipment.

Start the machine from the driver's seat only.


During start-up and shut-down procedures always
watch the indicators in accordance with the
Owners Manual.
Before setting the machine in motion, make sure
that nobody is at risk.
Before starting work or travelling with the machine,
check that the braking, steering, signalling and
lighting systems are fully functional.
Before setting the machine in motion always check
that the accessories have been safely stowed
away.
When travelling on public roads, ways and places,
always observe the valid traffic regulations and, if
necessary, make sure beforehand that the machine is in a condition compatible with these regulations.
In conditions of poor visibility and after dark always
switch on the lighting system.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 44

SAFETY INSTRUCTIONS

Persons accompanying the driver must be seated


on the passenger seats provided for this purpose.
When driving through underpasses or tunnels, over
bridges or under overhead lines, always make sure
that there is sufficient clearance.
Always keep at a distance from the edges of building pits and slopes.
Avoid any operation that might be a risk to machine stability.
Never travel across slopes; always keep the working equipment and the load close to the ground,
especially when travelling downhill.
On sloping terrain always adapt your travelling
speed to the prevailing ground conditions. Never
change to a lower gear on a slope but always before reaching it.
Before leaving the driver's seat always secure the
machine against inadvertent movement and unauthorized use. Shut off the engine.

WX210 - WX240

Special work in conjunction with utilization


of the machine - maintenance and repairs
during operation - disposal of parts and
consumables
Observe the adjusting, maintenance and inspection activities and intervals set out in the Owners
Manual, including information on the replacement
of parts and equipment. These activities may be
executed by skilled personnel only.
Brief operating personnel before beginning special
operations and maintenance work, and appoint a
person to supervise the activities.
In any work concerning the operation, conversion
or adjustment of the machine and its safetyoriented devices or any work related to maintenance, inspection and repair, always observe the
start-up and shut-down procedures set out in the
Owners Manual and the information on maintenance work.
Ensure that the maintenance area is adequately
secured.
If the machine is completely shut down for maintenance and repair work, it must be secured against
inadvertent starting by:
- removing the ignition key and
- attaching a warning sign.
Carry out maintenance and repair work only if the
machine is positioned on stable and level ground
and has been secured against inadvertent movement and buckling.
To avoid the risk of accidents, individual parts and
large assemblies being moved for replacement
purposes should be carefully attached to lifting
tackle and secured. Use only suitable and technically perfect lifting gear and suspension systems
with adequate lifting capacity. Never work or stand
under suspended loads.
The fastening of loads and the instructing of crane
operators should be entrusted to experienced persons only. The marshaller giving the instructions
must be within sight or sound of the operator.
For carrying out overhead assembly work always
use specially designed or otherwise safetyoriented ladders and working platforms. Never use
machine parts as a climbing aid.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

SAFETY INSTRUCTIONS

Wear a safety harness when carrying out maintenance work at greater heights.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt, snow and ice.
Clean the machine, especially connections and
threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/ repair
work. Never use aggressive detergents. Use lintfree cleaning rags.
Before cleaning the machine with water, steam jet
(high-pressure cleaning) or detergents, cover or
tape up all openings which have to be protected
against water, steam or detergent penetration for
safety and functional reasons. Special care must
be taken with electric motors and switchgear cabinets.
Ensure during cleaning of the machine that the
temperature sensors of the fire-warning and firefighting systems do not come into contact with hot
cleaning agents as this might activate the extinguishing system.
After cleaning, remove all covers and tapes applied
for that purpose.
After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections,
chafe marks and damage. Any defects found must
be rectified without delay.
Always tighten any screwed connections that have
been loosened during maintenance and repair
work.
Any safety devices removed for set-up, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work..
Ensure that all consumables and replaced parts
are disposed of safely and with minimum environmental impact.

0 - 45

Warning of special dangers


Electric energy
Use only original fuses with the specified current
rating. Switch off the machine immediately if trouble occurs in the electrical system.
When working with the machine, maintain a safe
distance from overhead electric lines. If work is to
be carried out close to overhead lines, the working
equipment must be kept well away from them.
Caution: life-threatening danger! Check out the
prescribed safety distances.
If your machine comes into contact with a live wire
- Do not leave the machine.
- Drive the machine out of the hazard zone and
warn others against approaching and touching
the machine.
- Have the live wire de-energized.
- Do not leave the machine until the damaged line
has been de-energized with certainty.
The electrical equipment of machines is to be inspected and checked at regular intervals. Defects
such as loose connections or scorched cables
must be rectified immediately.

Gas, dust, steam and smoke


Operate internal combustion engines and fueloperated heating systems only on adequately ventilated premises. Before starting the machine on
enclosed premises, make sure that there is sufficient ventilation.
Observe the regulations in force at the respective
site.
Carry out welding, flame-cutting and grinding work
on the machine only if this has been expressly
authorized, as there may be a risk of explosion and
fire.
Before carrying out welding, flame-cutting and
grinding operations, clean the machine and its
surroundings of dust and other inflammable substances and make sure that the premises are adequately ventilated (risk of explosion).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

0 - 46

SAFETY INSTRUCTIONS

WX210 - WX240

Hydraulic and pneumatic equipment

Oil, grease and other chemical substances

Check all lines, hoses and screwed connections


regularly for leaks and obvious damage. Repair
damage immediately. Splashed oil may cause
injury and fire.

When handling oil, grease and other chemical


substances, observe the product-related safety
regulations.

Depressurize all system sections and pressure


pipes (hydraulic system, compressed-air system)
to be removed in accordance with the specific instructions for the unit concerned before carrying
out any repair work.
Hydraulic and compressed-air lines must be laid
and fitted properly. Ensure that no connections are
interchanged. The fittings, lengths and quality of
the hoses must comply with the technical requirements.

Be careful when handling hot consumables (risk of


burning or scalding).

Transporting and towing; recommissioning


The machine must be towed, loaded and transported only in accordance with the Owners Manual.
For towing the machine observe the prescribed
transport position, admissible speed and route.
Use only appropriate means of transport and lifting
gear of adequate capacity.

Noise
During operation, all sound baffles of the machine
must be closed.

The recommissioning procedure must be strictly in


accordance with the Owners Manual.

Always wear the prescribed ear protectors.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

Service manual
Section 1 Technical Data and
Special Tools
WX210 - WX240

9-91270

1-2

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1-3

1-4

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Table of contents

SERVICE DATA GENERAL ........................................................................... 7


Foreword.......................................................................................................................................... 7
Technical characteristics ............................................................................................................... 8
Prospectuses in Annex .................................................................................................................................. 8
Data sheet for cylinders ................................................................................................................................. 9
Bucket-induced protrusion ........................................................................................................................... 10

SI- and Additional Units ............................................................................................................... 12


Quantities of Space and Mass ..................................................................................................................... 12
Time related Quantities................................................................................................................................ 13
Quantities of force, energy and power ......................................................................................................... 14

Conversions Tables Part 1........................................................................................................... 15


Conversion for units of legth ........................................................................................................................ 15
Conversion for units of area......................................................................................................................... 15
Conversion from foot and inch to metric mesures ....................................................................................... 16
Conversion from newtonmeter (Nm) into foot pounds (ft.lb)........................................................................ 17

Conversions Tables Part 2........................................................................................................... 25


Conversion table for units of pressure in gases, steam and fluids .............................................................. 25
Conversion table for units of power, energy and heat quantity ................................................................... 25
Conversion table for units of mechanical stress .......................................................................................... 25
Practically equivalent units for pressure and mechanical stress (stregth)................................................... 26
Units of temperature and conversion formulars........................................................................................... 26
Power, Energy and heat flow ....................................................................................................................... 27
Speed........................................................................................................................................................... 28
Units of mass (weight).................................................................................................................................. 29
Units of volume, flow rates........................................................................................................................... 30
Fuel consumption......................................................................................................................................... 31

Tightening Torques ...................................................................................................................... 32


General information...................................................................................................................................... 32
Units of measurement.................................................................................................................................. 32
Bolts with standard thread DIN 13 13 ....................................................................................................... 33
Bolts with metric fine thread DIN 13 13 .................................................................................................... 34
Tightening torques for SAE flange system ............................................................................................... 35
Tightening angles......................................................................................................................................... 35

Calculation Examples................................................................................................................... 36
Angles of Slope ............................................................................................................................................ 36
Travel Speed................................................................................................................................................ 36
Hydraulic outputs (pumps/motors) ............................................................................................................... 37
Stroking times of cylinders ........................................................................................................................... 37
Speeds of hydraulic motors ......................................................................................................................... 37

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1-5

Special tools for cylinders ........................................................................................................... 38


Screwed hex insert for piston nut................................................................................................................. 38
Sealing kit Assembly................................................................................................................................. 38
Scraper ring Assembly.............................................................................................................................. 38
Bushes - Dismantling ................................................................................................................................... 38
Rod guide assembly..................................................................................................................................... 39
Piston nut loosening and tightening ............................................................................................................. 39

Special tools for axles and gearboxes........................................................................................ 40


Axial stress meter......................................................................................................................................... 40
Bearing friction moment adjusting device .................................................................................................... 40
Driving tool for bushing ................................................................................................................................ 40
Driving tool for bushing ................................................................................................................................ 40
Assembly aid for shaft seals ........................................................................................................................ 40
Master shaft ................................................................................................................................................. 40
Master shaft ................................................................................................................................................. 41
Extraction device.......................................................................................................................................... 41
Driving tool ................................................................................................................................................... 41
Driving tool ................................................................................................................................................... 41
Driving tool ................................................................................................................................................... 41
Assembly aid................................................................................................................................................ 41
Assembly aid................................................................................................................................................ 42
Brake centering device ................................................................................................................................ 42
Tool handle .................................................................................................................................................. 42
Hydraulic pump ............................................................................................................................................ 42
Measuring device ......................................................................................................................................... 42
Threaded studs ............................................................................................................................................ 42
Driving tool for shaft seals............................................................................................................................ 43
Driving tool ................................................................................................................................................... 43
Driving tool ................................................................................................................................................... 43

Spacers .......................................................................................................................................... 44

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1-6

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

SERVICE DATA GENERAL

1-7

40000205-en

Foreword
Anyone involved with commissioning, operating, inspecting and servicing for this construction machine
must read through and acquaint
himself with the

When ordering spare parts, use only


the Part Numbers given in the spare
parts lists.

"OPERATING MANUAL"
and especially the Section
"FUNDAMENTAL
STRUCTIONS"

SAFETY

The Part Numbers given in the sections are not to be used when ordering spare parts. They are only intended to identify the component
being referred to.

IN-

before starting work.


The "Service Data" contains details which are important to the service staff. Data included in other
parts of the general documentation have been left
aside.
The set of documents for this construction machine
includes:
Operating manual
Spare parts list
"Technical Handbooks" (THB) and "Service Information" bulletins (SI) are, furthermore, to be considered as supplements to the general documentation.
Data regarding auxiliary units for operating ancillary or special systems, as well as data on machines produced only in small numbers, have not
been included.
Filling quantities are only approximate figures intended to help in stockholding the various fluids
and agents. Each unit has appropriate checking
systems, e.g. dipstick or checking screws, with
which the exact filling level can be checked.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1-8

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Technical characteristics

40000477-en

Prospectuses in Annex

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1-9

Data sheet for cylinders

Fig. 1

WX210

P/N

Piston

Piston
rod

Length

Stroke

Length

Cylinder barrel

Piston rod

Eye
c

Width
D

Eye
d

Width
E

Monoblock boom

7211 3778

135

85

10501.8

6301.8

16803.6

90++0.25
0.05

116 00.5

100 ++0.25
0.05

106 00.5

Boom adjusting

7210 4531

135

85

15651.8

9851.8

25503.6

90 ++0.25
0.05

116 00.5

100 ++0.25
0.05

106 00.5

Stick cylinder

7210 4546

135

95

19751.8

14001.8

33753.6

80

116 00.5

80

116 00.5

Bucket cylinder

7211 3790

115

80

16601.8

10751.8

27353.6

70 ++0.25
0.05

96 00.5

80++0.25
0.05

96 00.5

Neck

33 27 103

180

100

1360

745

2105

110++0.457
0.370

1261.2

110++0.457
0.370

126 0.5

Piston

Piston
rod

Length

Stroke

Length

WX240

P/N

Cylinder barrel

Piston rod

Eye
c

Width
D

Eye
d

Width
E

Monoblock boom

7211 2074

145

90

16301.8

10501.8

26803.6

90++0.25
0.05

116 00.5

100 ++0.25
0.05

106 00.5

Boom adjusting

7210 4481

145

90

15651.8

9851.8

25503.6

90++0.25
0.05

116 00.5

100 ++0.25
0.05

106 00.5

Stick cylinder

7210 4471

145

95

19751.8

14001.8

33753.6

90++0.25
0.05

123 00.5

90 ++0.25
0.05

123 00.5

Bucket cylinder

7211 1697

125

85

16651.8

10751.8

27403.6

80 ++0.25
0.05

123 00.5

80++0.25
0.05

123 00.5

Neck

33 26 713

185

100

1360

745

2105

110++0.457
0.370

1261.2

110++0.457
0.370

126 00.5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 10

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Bucket-induced protrusion

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 11

1 - 12

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

SI- and Additional Units

40000206-en

Quantities of Space and Mass


Quantity

Symbol

Unit
old

Conversion

new

for exact calculation

Explanation
Remark

for rough
calculation
(appr. 2%
inexact)

SI - Units

Selection of
additional units

Length

mm, cm,
dm, m, km

mm, km

Area

mm, cm,
dm, m

mm, cm

V, Vn

mm, cm,
dm, m, l

mm, cm,
dm, l

Mass

mg, g, kg,
Mg=t, (kp s/m)

kg

mg, g,
Mg, t

Density

g/cm, kg/dm,
4
(kp s/m )

kg/m

g/cm,
kg/dm

Inertia
moment

kp m

kg m

Mg m

Specific
volume

m/kg

m/Mg

Volume

(kp m s)
m/kg, m/t

1 kp m s =
9,81 kg m

1 kp m s =
10 kg m

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 13

Time related Quantities


Quantity

Symbol

Unit
old

Conversion

new

for exact
calculation

Explanation
Remark

for rough
calculation
(appr. 2%
inexact)

SI - Units

Selection of
additional units
ms, min, h,
d

Time

s, min, h,
d = day

Frequency

Hz

Hz

Rate of revolutions

U/min

1/s

1/min

Speed

m/s, km/h

m/s

km/h

Acceleration

m/s

m/s

Volume flow

m/s, m/min,
m/h

m/s

Mass flow

kg/s, kg/min,
kg/h

kf/s

Heat flow

(kcal/h)

kW, MW

1kcal/h =
1.163W

1kcal/h =
1.2W

b, bs

kg/PSh
g/PSh

kg/J

g/(kWh)

1g/(PSh) =
1.359g/(kWh)

1g/(PSh) =
1.36g/(kWh)

Specific fuel
and oil
consumption

1 Hz 1/s
s = min/60

m/min,
l/h

1W = 1J/s =
1Nm/s

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 14

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Quantities of force, energy and power


Quantity

Symbol

Unit
old

Conversion

new

for exact
calculation

Explanation
Remark

for rough
calculation
(appr. 2%
inexact)

Force

SI - Units

Selection of
additional units

(dyn, p)

N (Newton)

MN, kN,
mN

1kp =
1kg x 9,81m/s
= 9,81N

1kp = 10N

1N =
1kg x 1m/s =
1kg m/s

P, Pi,
Pe,
P, Pu

(kp/cm,at,atm)
(mWS, Torr)
(mmHg)

N/m
Pa (Pascal)

bar, mbar

1kp/cm =
0.981bar
1 atm =
1.013bar
1mWS =
0.098bar

1 kp/cm =
1bar
1mWS =
0.1bar

1 N/m =
1Pa
1Pa =
-5
10 bar
1bar =
5
10 N/m

Mechanical
stress

(kp/cm)
(kp/mm)

N/m, pa

N/mm

1 kp/mm =
9.81N/mm
1kp/cm =
9.81N/cm

1 kp/mm =
10N/mm
1kp/cm =
10N/cm

1N/m = 1Pa

Energy

(kpm)

J (Joule)

MJ, kJ,
kW h

1kpm = 9.81J

1kpm = 10J

3.6MJ =
1kWh
1J = 1NM =
1Ws

Heat capacy

(cal, erg)

J (Joule)

MJ, kJ,
kW h

1 kcal =
4.19kJ

Power

(PS), W

kW, MW

1PS =
0.735499 kW
1kW =
1.359622 PS

1PS =
0.74kW
1kW =
1.39 PS

Torque, bending moment

(kp m)

Nm

Ncm

1kpm =
9.81Nm

1kpm =
10Nm

Pressure
(of Fluids)

3.6MJ =
1kWh
1J = 1NM =
1Ws
1W = 1J/s =
1Nm/s

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 15

Conversions Tables Part 1

40000207-en

Conversion for units of length


Length

in

ft

yd

mile

1 inch

0.0833

0.0278

1foot

12

0.3333

0.00019

1 yard

36

1 statute mile

63360

5280

1 UK nautic mile

72960

1 cm
1m

UK n mile

cm

2.54

0.0254

0.00016

30.48

0.3048

0.00057

0.00049

91.44

0.9144

1760

0.86842

1609.3

6080

2026.7

1.15151

1853.2

0.3937

0.0328

0.0109

39370

3.2808

1.0936

0.00062

yd

sqmile

0.01

0.00054

100

acre

cm

Conversion for units of area


Area

in

ft

1 square inch

0.0069

1 square foot

144

0.1111

1 square yard

1296

6.4516

1 square mile
1 acre

43560

1 cm

0.1550

1 m

1550.0

10.764

4840
1.1960

929.03 0.0929
0.00021
1

460

0.00156

8361.3 0.8361

4046.9
1

0.0001

10000

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 16

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Conversion from foot and inch to metric mesures


1 in = 25.4 mm (exact)
ft

1 ft = 12 in = 304.8 mm

Example: 4ft 2 in = 1.27m

in
+0

+1

+2

+3

+4

+5

+6

+7

+8

+9

+10

+11

0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286 0.2540 0.2794

0.3048 0.3302 0.3556 0.3810 0.4064 0.4318 0.4572 0.4826 0.5080 0.5334 0.5588 0.5842

0.6096 0.6350 0.6604 0.6858 0.7112 0.7366 0.7620 0.7874 0.8128 0.8382 0.8636 0.8890

0.9144 0.9398 0.9652 0.9906 1.0160 1.0414 1.0668 1.0922 1.1176 1.1430 1.1684 1.1938

1.2192 1.2446 1.2700 1.2954 1.3208 1.3462 1.3716 1.3970 1.4224 1.4478 1.4732 1.4986

1.5240 1.5494 1.5748 1.6002 1.6256 1.6510 1.6764 1.7018 1.7272 1.7526 1.7780 1.8034

1.8288 1.8542 1.8796 1.9050 1.9304 1.9558 1.9812 2.0066 2.0320 2.0574 2.0828 2.1082

2.1336 2.1590 2.1844 2.2098 2.2352 2.2606 2.2860 2.3114 2.3368 2.3622 2.3876 2.4130

2.4384 2.4638 2.4892 2.5146 2.5400 2.5654 2.5908 2.6162 2.6416 2.6670 2.6924 2.7178

2.7432 2.7686 2.7940 2.8194 2.8448 2.8702 2.8956 2.9210 2.9464 2.9718 2.9972 3.0226

10

3.0480 3.0734 3.0988 3.1242 3.1496 3.1750 3.2004 3.2258 3.2512 3.2766 3.3020 3.3274

11

3.3528 3.3782 3.4036 3.4290 3.4544 3.4798 3.5052 3.5306 3.5560 3.5814 3.6068 3.6322

12

3.6576 3.6830 3.7000 3.7338 3.7592 3.7846 3.8100 3.8354 3.8608 3.8862 3.9116 3.9370

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 17

Conversion from newtonmeter (Nm) into foot pounds (ft.lb)


Nm

10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
510
520
530
540
550
560
570
580
590
600
610
620
630
640
650
660
670
680
690
700

7.376
14.751
22.127
29.502
36.878
44.254
51.629
59.005
66.380
73.756
81.132
88.507
95.883
103.258
110.634
118.010
125.385
132.761
140.136
147.512
154.888
162.263
169.639
177.014
184.390
191.766
199.141
206.517
213.892
221.268
228.644
236.019
243.395
250.770
258.146
265.521
272.897
280.273
287.648
295.024
302.399
309.775
317.151
324.526
331.902
339.278
346.653
354.029
361.404
368.780
376.156
383.531
390.907
398.282
405.658
413.033
420.409
427.785
435.160
442.536
449.911
457.287
464.663
472.038
479.414
486.790
494.165
501.541
508.916
516.292

8.113
15.489
22.864
30.240
37.616
44.991
52.367
59.742
67.118
74.494
81.869
89.245
96.620
103.996
111.372
118.747
126.123
133.498
140.874
148.250
155.625
163.001
170.376
177.752
185.128
192.503
199.879
207.254
214.630
222.006
229.381
236.757
244.132
251.508
258.884
266.259
273.635
281.010
288.386
295.761
303.137
310.513
317.888
325.264
332.639
340.015
347.391
354.766
362.142
369.517
376.893
384.269
391.644
399.020
406.396
413.771
421.147
428.522
435.898
443.273
450.649
458.025
465.400
472.776
480.151
487.527
494.903
502.278
509.654
517.030

8.851
16.226
23.602
30.978
38.353
45.729
53.104
60.480
67.856
75.231
82.607
89.982
97.358
104.734
112.109
119.485
126.860
134.236
141.612
148.987
156.363
163.738
171.114
178.490
185.865
193.241
200.616
207.992
215.368
222.743
230.119
237.494
244.870
252.245
259.621
266.997
274.372
281.748
289.123
296.499
303.875
311.250
318.626
326.001
333.377
340.753
348.128
355.504
362.879
370.255
377.631
385.006
392.382
399.757
407.133
414.509
421.884
429.260
436.635
444.011
451.386
458.762
466.138
473.513
480.889
488.265
495.640
503.016
510.391
517.767

9.588
16.964
24.339
31.715
39.091
46.466
53.842
61.217
68.593
75.969
83.344
90.720
98.095
105.471
112.847
120.222
127.598
134.973
142.349
149.725
157.100
164.476
171.851
179.227
186.603
193.978
201.354
208.729
216.105
223.481
230.856
238.232
245.607
252.983
260.359
267.734
275.110
282.485
289.861
297.237
304.612
311.988
319.363
326.739
334.115
341.490
348.866
356.241
363.617
370.992
378.368
385.744
393.119
400.495
407.871
415.246
422.622
429.997
437.373
444.749
452.124
459.500
466.875
474.251
481.626
489.002
496.378
503.753
511.129
518.505

10.326
17.701
25.077
32.453
39.828
47.204
54.579
61.955
69.331
76.706
84.082
91.457
98.833
106.209
113.584
120.960
128.335
135.711
143.087
150.462
157.838
165.213
172.589
179.965
187.340
194.716
202.091
209.467
216.843
224.218
231.594
238.969
246.345
253.721
261.096
268.472
275.847
283.223
290.598
297.974
305.350
312.725
320.101
327.477
334.852
342.228
349.603
356.979
364.354
371.730
379.106
386.481
393.857
401.232
408.608
415.984
423.359
430.735
438.111
445.486
452.862
460.237
467.613
474.989
482.364
489.740
497.115
504.491
511.866
519.242

11.063
18.439
25.815
33.190
40.566
47.941
55.317
62.693
70.068
77.444
84.819
92.195
99.571
106.946
114.322
121.697
129.073
136.449
143.824
151.200
158.575
165.951
173.327
180.702
188.078
195.453
202.829
210.205
217.580
224.956
232.331
239.707
247.083
254.458
261.834
269.209
276.585
283.960
291.336
298.712
306.087
313.463
320.838
328.214
335.590
342.965
350.341
357.717
365.092
372.468
379.843
387.219
394.594
401.970
409.346
416.721
424.097
431.472
438.848
446.224
453.599
460.975
468.350
475.726
483.102
490.477
497.853
505.229
512.604
519.980

11.801
19.177
26.552
33.928
41.303
48.679
56.055
63.430
70.806
78.181
85.557
92.933
100.308
107.684
115.059
122.435
129.811
137.186
144.562
151.937
159.313
166.689
174.064
181.440
188.815
196.191
203.567
210.942
218.318
225.693
233.069
240.445
247.820
255.196
262.571
269.947
277.323
284.698
292.074
299.449
306.825
314.200
321.576
328.952
336.327
343.703
351.078
358.454
365.830
373.205
380.581
387.957
395.332
402.708
410.083
417.459
424.834
432.210
439.586
446.961
454.337
461.712
469.088
476.464
483.839
491.215
498.590
505.966
513.342
520.717

12.539
19.914
27.290
34.665
42.041
49.417
56.792
64.168
71.543
78.919
86.295
93.670
101.046
108.421
115.797
123.173
130.548
137.924
145.299
152.675
160.051
167.426
174.802
182.177
189.553
196.929
204.304
211.680
219.055
226.431
233.807
241.182
248.558
255.933
263.309
270.684
278.060
285.436
292.811
300.187
307.562
314.938
322.313
329.689
337.065
344.440
351.816
359.192
366.567
373.943
381.318
388.694
396.070
403.445
410.821
418.196
425.572
432.948
440.323
447.699
455.074
462.450
469.826
477.201
484.577
491.952
499.328
506.704
514.079
521.455

13.276
20.652
28.027
35.403
42.778
50.154
57.530
64.905
72.281
79.656
87.032
94.408
101.783
109.159
116.534
123.910
131.286
138.661
146.037
153.412
160.788
168.164
175.539
182.915
190.290
197.666
205.042
212.417
219.793
227.168
234.544
241.920
249.295
256.671
264.046
271.422
278.798
286.173
293.549
300.924
308.300
315.676
323.051
330.427
337.802
345.178
352.553
359.929
367.305
374.680
382.056
389.432
396.807
404.183
411.558
418.934
426.310
433.685
441.061
448.436
455.812
463.187
470.563
477.939
485.314
492.690
500.065
507.441
514.817
522.192

14.014
21.389
8.765
36.140
43.516
50.892
58.267
65.643
73.018
80.394
87.770
95.145
102.521
109.896
117.272
124.648
132.023
139.399
146.774
154.150
161.526
168.901
176.277
183.652
191.028
198.404
205.779
213.155
220.530
227.906
235.282
242.657
250.033
257.408
264.784
272.159
279.535
286.911
294.286
301.662
309.038
316.413
323.789
331.164
338.540
345.916
353.291
360.667
368.042
375.418
382.793
390.169
397.545
404.920
412.296
419.671
427.047
434.423
441.798
449.174
456.550
463.925
471.301
478.676
486.052
493.427
500.803
508.179
515.554
522.930

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 18

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Nm

710
720
730
740
750
760
770
780
790
800
810
820
830
840
850
860
870
880
890
900
910
920
930
940
950
960
970
980
990
1000
1010
1020
1030
1040
1050
1060
1070
1080
1090
1100
1110
1120
1130
1140
1150
1160
1170
1180
1190
1200
1210
1220
1230
1240
1250
1260
1270
1280
1290
1300
1310
1320
1330
1340
1350
1360
1370
1380
1390
1400

523.667
531.043
538.419
545.794
553.170
560.545
567.921
575.297
582.672
590.048
597.423
604.799
612.175
619.550
626.926
634.302
641.677
649.053
656.428
663.804
671.179
678.555
685.931
693.306
700.682
708.057
715.433
722.809
730.184
737.560
744.936
752.311
759.687
767.062
774.438
781.813
789.189
796.565
803.940
811.316
818.691
826.067
833.443
840.818
848.194
855.569
862.945
870.321
877.696
885.072
892.448
899.823
907.199
914.574
921.950
929.325
936.701
944.077
951.452
958.828
966.203
973.579
980.955
988.330
995.706
1003.082
1010.457
1017.833
1025.208
1032.584

524.405
531.781
539.156
546.532
553.907
561.283
568.659
576.034
583.410
590.785
598.161
605.537
612.912
620.288
627.663
635.039
642.415
649.790
657.166
664.542
671.917
679.293
686.668
694.044
701.419
708.795
716.171
723.546
730.922
738.297
745.673
753.049
760.424
767.800
775.175
782.551
789.927
797.302
804.678
812.053
819.429
826.805
834.180
841.556
848.931
856.307
863.683
871.058
878.434
885.809
893.185
900.561
907.936
915.312
922.687
930.063
937.439
944.814
952.190
959.565
966.941
974.317
981.692
989.068
996.443
1003.819
1011.195
1018.570
1025.946
1033.321

525.143
532.518
539.894
547.269
554.645
562.021
569.396
576.772
584.147
591.523
598.899
606.274
613.650
621.025
628.401
635.777
643.152
650.528
657.903
665.279
672.655
680.030
687.406
694.781
702.157
709.532
716.908
724.284
731.659
739.035
746.411
753.786
761.162
768.537
775.913
783.289
790.664
798.040
805.415
812.791
820.167
827.542
834.918
842.293
849.669
857.045
864.420
871.796
879.171
886.547
893.923
901.298
908.674
916.049
923.425
930.801
938.176
945.552
952.927
960.303
967.678
975.054
982.430
989.805
997.181
1004.557
1011.932
1019.308
1026.683
1034.059

525.880
533.256
540.631
548.007
555.383
562.758
570.134
577.509
584.885
592.260
599.636
607.012
614.387
621.763
629.138
636.514
643.890
651.265
658.641
666.017
673.392
680.768
688.143
695.519
702.895
710.270
717.646
725.021
732.397
739.772
747.148
754.524
761.899
769.275
776.651
784.026
791.402
798.777
806.153
813.529
820.904
828.280
835.655
843.031
850.406
857.782
865.158
872.533
879.909
887.284
894.660
902.036
909.411
916.787
924.163
931.538
938.914
946.289
953.665
961.041
968.416
975.792
983.167
990.543
997.918
1005.294
1012.670
1020.045
1027.421
1034.797

526.618
533.993
541.369
548.744
556.120
563.496
570.871
578.247
585.623
592.998
600.374
607.749
615.125
622.500
629.876
637.252
644.627
652.003
659.378
666.754
674.130
681.505
688.881
696.257
703.632
711.008
718.383
725.759
733.135
740.510
747.886
755.261
762.637
770.012
777.388
784.764
792.139
799.515
806.890
814.266
821.642
829.017
836.393
843.769
851.144
858.520
865.895
873.271
880.646
888.022
895.398
902.773
910.149
917.524
924.900
932.276
939.651
947.027
954.403
961.778
969.154
976.529
983.905
991.281
998.656
1006.032
1013.407
1020.783
1028.158
1035.534

527.355
534.731
542.106
549.482
556.858
564.233
571.609
578.984
586.360
593.736
601.111
608.487
615.863
623.238
630.614
637.989
645.365
652.740
660.116
667.492
674.867
682.243
689.618
696.994
704.370
711.745
719.121
726.496
733.872
741.248
748.623
755.999
763.375
770.750
778.126
785.501
792.877
800.252
807.628
815.004
822.379
829.755
837.130
844.506
851.882
859.257
866.633
874.009
881.384
888.760
896.135
903.511
910.886
918.262
925.638
933.013
940.389
947.764
955.140
962.516
969.891
977.267
984.642
992.018
999.394
1006.769
1014.145
1021.521
1028.896
1036.272

528.093
535.469
542.844
550.220
557.595
564.971
572.346
579.722
587.098
594.473
601.849
609.224
616.600
623.976
631.351
638.727
646.102
653.478
660.854
668.229
675.605
682.980
690.356
697.732
705.107
712.483
719.858
727.234
734.610
741.985
749.361
756.736
764.112
771.488
778.863
786.239
793.615
800.990
808.366
815.741
823.117
830.492
837.868
845.244
852.619
859.995
867.370
874.746
882.122
889.497
896.873
904.248
911.624
919.000
926.375
933.751
941.126
948.502
955.878
963.253
970.629
978.004
985.380
992.756
1000.131
1007.507
1014.882
1022.258
1029.634
1037.009

528.830
536.206
543.582
550.957
558.333
565.708
573.084
580.459
587.835
595.211
602.586
609.962
617.338
624.713
632.089
639.464
646.840
654.216
661.591
668.967
676.342
683.718
691.094
698.469
705.845
713.220
720.596
727.972
735.347
742.723
750.098
757.474
764.850
772.225
779.601
786.976
794.352
801.728
809.103
816.479
823.854
831.230
838.605
845.981
853.357
860.732
868.108
875.484
882.859
890.235
897.610
904.986
912.362
919.737
927.113
934.488
941.864
949.240
956.615
963.991
971.366
978.742
986.118
993.493
1000.869
1008.244
1015.620
1022.996
1030.371
1037.747

529.568
536.944
544.319
551.695
559.070
566.446
573.822
581.197
588.573
595.948
603.324
610.699
618.075
625.451
632.826
640.202
647.578
654.953
662.329
669.704
677.080
684.456
691.831
699.207
706.582
713.958
721.333
728.709
736.085
743.460
750.836
758.211
765.587
772.963
780.338
787.714
795.090
802.465
809.841
817.216
824.592
831.968
839.343
846.719
854.094
861.470
868.845
876.221
883.597
890.972
898.348
905.724
913.099
920.475
927.850
935.226
942.602
949.977
957.353
964.728
972.104
979.479
986.855
994.231
1001.606
1008.982
1016.357
1023.733
1031.109
1038.484

530.305
537.681
545.057
552.432
559.808
567.184
574.559
581.935
589.310
596.686
604.062
611.437
618.813
626.188
633.564
640.939
648.315
655.691
663.066
670.442
677.817
685.193
692.569
699.944
707.320
714.696
722.071
729.447
736.822
744.198
751.573
758.949
766.325
773.700
781.076
788.451
795.827
803.203
810.578
817.954
825.330
832.705
840.081
847.456
854.832
862.208
869.583
876.959
884.334
891.710
899.085
906.461
913.837
921.212
928.588
935.963
943.339
950.715
958.090
965.466
972.842
980.217
987.593
994.968
1002.344
1009.719
1017.095
1024.471
1031.846
1039.222

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 19

Nm

1410
1420
1430
1440
1450
1460
1470
1480
1490
1500
1510
1520
1530
1540
1550
1560
1570
1580
1590
1600
1610
1620
1630
1640
1650
1660
1670
1680
1690
1700
1710
1720
1730
1740
1750
1760
1770
1780
1790
1800
1810
1820
1830
1840
1850
1860
1870
1880
1890
1900
1910
1920
1930
1940
1950
1960
1970
1980
1990
2000
2010
2020
2030
2040
2050
2060
2070
2080
2090
2100

1039.959
1047.335
1054.711
1062.086
1069.462
1076.837
1084.213
1091.589
1098.964
1106.340
1113.715
1121.091
1128.467
1135.842
1143.218
1150.594
1157.969
1165.345
1172.720
1180.096
1187.471
1194.847
1202.223
1209.598
1216.974
1224.349
1231.725
1239.101
1246.476
1253.852
1261.228
1268.603
1275.979
1283.354
1290.730
1298.105
1305.481
1312.857
1320.232
1327.608
1334.983
1342.359
1349.735
1357.110
1364.486
1371.861
1379.237
1386.613
1393.988
1401.364
1408.740
1416.115
1423.491
1430.866
1438.242
1445.617
1452.993
1460.369
1467.744
1475.120
1482.495
1489.871
1497.247
1504.622
1511.998
1519.374
1526.749
1534.125
1541.500
1548.876

1040.697
1048.073
1055.448
1062.824
1070.199
1077.575
1084.951
1092.326
1099.702
1107.077
1114.453
1121.829
1129.204
1136.580
1143.955
1151.331
1158.707
1166.082
1173.458
1180.833
1188.209
1195.585
1202.960
1210.336
1217.711
1225.087
1232.463
1239.838
1247.214
1254.589
1261.965
1269.341
1276.716
1284.092
1291.467
1298.843
1306.219
1313.594
1320.970
1328.345
1335.721
1343.097
1350.472
1357.848
1365.223
1372.599
1379.975
1387.350
1394.726
1402.101
1409.477
1416.853
1424.228
1431.604
1438.979
1446.355
1453.730
1461.106
1468.482
1475.857
1483.233
1490.609
1497.984
1505.360
1512.735
1520.111
1527.487
1534.862
1542.238
1549.613

1041.435
1048.810
1056.186
1063.561
1070.937
1078.312
1085.688
1093.064
1100.439
1107.815
1115.191
1122.566
1129.942
1137.317
1144.693
1152.069
1159.444
1166.820
1174.195
1181.571
1188.947
1196.322
1203.698
1211.073
1218.449
1225.824
1233.200
1240.576
1247.951
1255.327
1262.703
1270.078
1277.454
1284.829
1292.205
1299.581
1306.956
1314.332
1321.707
1329.083
1336.458
1343.834
1351.210
1358.585
1365.961
1373.337
1380.712
1388.088
1395.463
1402.839
1410.215
1417.590
1424.966
1432.341
1439.717
1447.093
1454.468
1461.844
1469.219
1476.595
1483.970
1491.346
1498.722
1506.097
1513.473
1520.849
1528.224
1535.600
1542.975
1550.351

1042.172
1049.548
1056.923
1064.299
1071.675
1079.050
1086.426
1093.801
1101.177
1108.552
1115.928
1123.304
1130.679
1138.055
1145.430
1152.806
1160.182
1167.557
1174.933
1182.309
1189.684
1197.060
1204.435
1211.811
1219.187
1226.562
1233.938
1241.313
1248.689
1256.064
1263.440
1270.816
1278.191
1285.567
1292.943
1300.318
1307.694
1315.069
1322.445
1329.821
1337.196
1344.572
1351.947
1359.323
1366.698
1374.074
1381.450
1388.825
1396.201
1403.576
1410.952
1418.328
1425.703
1433.079
1440.455
1447.830
1455.206
1462.581
1469.957
1477.333
1484.708
1492.084
1499.459
1506.835
1514.210
1521.586
1528.962
1536.337
1543.713
1551.089

1042.910
1050.285
1057.661
1065.036
1072.412
1079.788
1087.163
1094.539
1101.915
1109.290
1116.666
1124.041
1131.417
1138.792
1146.168
1153.544
1160.919
1168.295
1175.670
1183.046
1190.422
1197.797
1205.173
1212.549
1219.924
1227.300
1234.675
1242.051
1249.427
1256.802
1264.178
1271.553
1278.929
1286.304
1293.680
1301.056
1308.431
1315.807
1323.182
1330.558
1337.934
1345.309
1352.685
1360.061
1367.436
1374.812
1382.187
1389.563
1396.938
1404.314
1411.690
1419.065
1426.441
1433.816
1441.192
1448.568
1455.943
1463.319
1470.695
1478.070
1485.446
1492.821
1500.197
1507.573
1514.948
1522.324
1529.699
1537.075
1544.450
1551.826

1043.647
1051.023
1058.398
1065.774
1073.150
1080.525
1087.901
1095.276
1102.652
1110.028
1117.403
1124.779
1132.155
1139.530
1146.906
1154.281
1161.657
1169.032
1176.408
1183.784
1191.159
1198.535
1205.910
1213.286
1220.662
1228.037
1235.413
1242.788
1250.164
1257.540
1264.915
1272.291
1279.667
1287.042
1294.418
1301.793
1309.169
1316.544
1323.920
1331.296
1338.671
1346.047
1353.422
1360.798
1368.174
1375.549
1382.925
1390.301
1397.676
1405.052
1412.427
1419.803
1427.178
1434.554
1441.930
1449.305
1456.681
1464.056
1471.432
1478.808
1486.183
1493.559
1500.934
1508.310
1515.686
1523.061
1530.437
1537.812
1545.188
1552.564

1044.385
1051.760
1059.136
1066.512
1073.887
1081.263
1088.638
1096.014
1103.390
1110.765
1118.141
1125.516
1132.892
1140.268
1147.643
1155.019
1162.394
1169.770
1177.146
1184.521
1191.897
1199.272
1206.648
1214.024
1221.399
1228.775
1236.150
1243.526
1250.902
1258.277
1265.653
1273.028
1280.404
1287.780
1295.155
1302.531
1309.906
1317.282
1324.657
1332.033
1339.409
1346.784
1354.160
1361.536
1368.911
1376.287
1383.662
1391.038
1398.414
1405.789
1413.165
1420.540
1427.916
1435.292
1442.667
1450.043
1457.418
1464.794
1472.170
1479.545
1486.921
1494.296
1501.672
1509.048
1516.423
1523.799
1531.174
1538.550
1545.926
1553.301

1045.122
1052.498
1059.874
1067.249
1074.625
1082.000
1089.376
1096.751
1104.127
1111.503
1118.878
1126.254
1133.630
1141.005
1148.381
1155.756
1163.132
1170.508
1177.883
1185.259
1192.634
1200.010
1207.385
1214.761
1222.137
1229.512
1236.888
1244.264
1251.639
1259.015
1266.390
1273.766
1281.142
1288.517
1295.893
1303.268
1310.644
1318.020
1325.395
1332.771
1340.146
1347.522
1354.897
1362.273
1369.649
1377.024
1384.400
1391.776
1399.151
1406.527
1413.902
1421.278
1428.654
1436.029
1443.405
1450.780
1458.156
1465.531
1472.907
1480.283
1487.658
1495.034
1502.409
1509.785
1517.161
1524.536
1531.912
1539.288
1546.663
1554.039

1045.860
1053.236
1060.611
1067.987
1075.362
1082.738
1090.114
1097.489
1104.865
1112.240
1119.616
1126.991
1134.367
1141.743
1149.118
1156.494
1163.870
1171.245
1178.621
1185.996
1193.372
1200.748
1208.123
1215.499
1222.874
1230.250
1237.625
1245.001
1252.377
1259.752
1267.128
1274.503
1281.879
1289.255
1296.630
1304.006
1311.382
1318.757
1326.133
1333.508
1340.884
1348.260
1355.635
1363.011
1370.386
1377.762
1385.137
1392.513
1399.889
1407.264
1414.640
1422.016
1429.391
1436.767
1444.142
1451.518
1458.894
1466.269
1473.645
1481.020
1488.396
1495.771
1503.147
1510.523
1517.898
1525.274
1532.649
1540.025
1547.401
1554.776

1046.597
1053.973
1061.349
1068.724
1076.100
1083.476
1090.851
1098.227
1105.602
1112.978
1120.354
1127.729
1135.105
1142.480
1149.856
1157.231
1164.607
1171.983
1179.358
1186.734
1194.109
1201.485
1208.861
1216.236
1223.612
1230.988
1238.363
1245.739
1253.114
1260.490
1267.865
1275.241
1282.617
1289.992
1297.368
1304.743
1312.199
1319.495
1326.870
1334.246
1341.622
1348.997
1356.373
1363.748
1371.124
1378.500
1385.875
1393.251
1400.626
1408.002
1415.377
1422.753
1430.129
1437.504
1444.880
1452.255
1459.631
1467.007
1474.382
1481.758
1489.134
1496.509
1503.885
1511.260
1518.636
1526.011
1533.387
1540.763
1548.138
1555.514

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 20

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Nm

2110
2120
2130
2140
2150
2160
2170
2180
2190
2200
2210
2220
2230
2240
2250
2260
2270
2280
2290
2300
2310
2320
2330
2340
2350
2360
2370
2380
2390
2400
2410
2420
2430
2440
2450
2460
2470
2480
2490
2500
2510
2520
2530
2540
2550
2560
2570
2580
2590
2600
2610
2620
2630
2640
2650
2660
2670
2680
2690
2700
2710
2720
2730
2740
2750
2760
2770
2780
2790
2800

1556.251
1563.627
1571.003
1578.378
1585.754
1593.129
1600.505
1607.881
1615.256
1622.632
1630.007
1637.383
1644.759
1652.134
1659.510
1666.885
1674.261
1681.637
1689.012
1696.388
1703.763
1711.139
1718.515
1725.890
1733.266
1740.641
1748.017
1755.393
1762.768
1770.144
1777.520
1784.895
1792.271
1799.646
1807.022
1814.397
1821.773
1829.149
1836.524
1843.900
1851.275
1858.651
1866.027
1873.402
1880.778
1888.153
1895.529
1902.905
1910.280
1917.656
1925.031
1932.407
1939.783
1947.158
1954.534
1961.909
1969.285
1976.661
1984.036
1991.412
1998.787
2006.163
2013.539
2020.914
2028.290
2035.666
2043.041
2050.417
2057.792
2065.168

1556.989
1564.365
1571.740
1579.116
1586.491
1593.867
1601.243
1608.618
1615.994
1623.369
1630.745
1638.121
1645.496
1652.872
1660.247
1667.623
1674.999
1682.374
1689.750
1697.125
1704.501
1711.876
1719.252
1726.628
1734.003
1741.379
1748.755
1756.130
1763.506
1770.881
1778.257
1785.633
1793.008
1800.384
1807.759
1815.135
1822.510
1829.886
1837.262
1844.637
1852.013
1859.389
1866.764
1874.140
1881.515
1888.891
1896.267
1903.642
1911.018
1918.393
1925.769
1933.145
1940.520
1947.896
1955.271
1962.647
1970.022
1977.398
1984.774
1992.149
1999.525
2006.901
2014.276
2021.652
2029.027
2036.403
2043.779
2051.154
2058.530
2065.905

1557.727
1565.102
1572.478
1579.853
1587.229
1594.604
1601.980
1609.356
1616.731
1624.107
1631.482
1638.858
1646.234
1653.609
1660.985
1668.361
1675.736
1683.112
1690.487
1697.863
1705.239
1712.614
1719.990
1727.365
1734.741
1742.116
1749.492
1756.868
1764.243
1771.619
1778.995
1786.370
1793.746
1801.121
1808.497
1815.873
1823.248
1830.624
1837.999
1845.375
1852.750
1860.126
1867.502
1874.877
1882.253
1889.628
1897.004
1904.380
1911.755
1919.131
1926.507
1933.882
1941.258
1948.633
1956.009
1963.385
1970.760
1978.136
1985.511
1992.887
2000.262
2007.638
2015.014
2022.389
2029.765
2037.141
2044.516
2051.892
2059.267
2066.643

1558.464
1565.840
1573.215
1580.591
1587.967
1595.342
1602.718
1610.093
1617.469
1624.844
1632.220
1639.596
1646.971
1654.347
1661.722
1669.098
1676.474
1683.849
1691.225
1698.601
1705.976
1713.352
1720.727
1728.103
1735.479
1742.854
1750.230
1757.605
1764.981
1772.356
1779.732
1787.108
1794.483
1801.859
1809.234
1816.610
1823.986
1831.361
1838.737
1846.113
1853.488
1860.864
1868.239
1875.615
1882.990
1890.366
1897.742
1905.117
1912.493
1919.868
1927.244
1934.620
1941.995
1949.371
1956.747
1964.122
1971.498
1978.873
1986.249
1993.625
2001.000
2008.376
2015.751
2023.127
2030.502
2037.878
2045.254
2052.629
2060.005
2067.380

1559.202
1566.577
1573.953
1581.328
1588.704
1596.080
1603.455
1610.831
1618.207
1625.582
1632.958
1640.333
1647.709
1655.084
1662.460
1669.836
1677.211
1684.587
1691.962
1699.338
1706.714
1714.089
1721.465
1728.841
1736.216
1743.592
1750.967
1758.343
1765.719
1773.094
1780.470
1787.845
1795.221
1802.596
1809.972
1817.348
1824.723
1832.099
1839.474
1846.850
1854.226
1861.601
1868.977
1876.353
1883.728
1891.104
1898.479
1905.855
1913.230
1920.606
1927.982
1935.357
1942.733
1950.108
1957.484
1964.860
1972.235
1979.611
1986.986
1994.362
2001.738
2009.113
2016.489
2023.865
2031.240
2038.616
2045.991
2053.367
2060.742
2068.118

1559.939
1567.315
1574.690
1582.066
1589.442
1596.817
1604.193
1611.568
1618.944
1626.320
1633.695
1641.071
1648.447
1655.822
1663.198
1670.573
1677.949
1685.324
1692.700
1700.076
1707.451
1714.827
1722.202
1729.578
1736.954
1744.329
1751.705
1759.080
1766.456
1773.832
1781.207
1788.583
1795.958
1803.334
1810.710
1818.085
1825.461
1832.836
1840.212
1847.588
1854.963
1862.339
1869.714
1877.090
1884.466
1891.841
1899.217
1906.593
1913.968
1921.344
1928.719
1936.095
1943.470
1950.846
1958.222
1965.597
1972.973
1980.348
1987.724
1995.100
2002.475
2009.851
2017.226
2024.602
2031.978
2039.353
2046.729
2054.104
2061.480
2068.856

1560.677
1568.052
1575.428
1582.803
1590.179
1597.555
1604.930
1612.306
1619.682
1627.057
1634.433
1641.808
1649.184
1656.560
1663.935
1671.311
1678.686
1686.062
1693.437
1700.813
1708.189
1715.564
1722.940
1730.316
1737.691
1745.067
1752.442
1759.818
1767.194
1774.569
1781.945
1789.320
1796.696
1804.072
1811.447
1818.823
1826.198
1833.574
1840.949
1848.325
1855.701
1863.076
1870.452
1877.828
1885.203
1892.579
1899.954
1907.330
1914.706
1922.081
1929.457
1936.832
1944.208
1951.583
1958.959
1966.335
1973.710
1981.086
1988.462
1995.837
2003.213
2010.588
2017.964
2025.340
2032.715
2040.091
2047.466
2054.842
2062.218
2069.593

1561.414
1568.790
1576.166
1583.541
1590.917
1598.292
1605.668
1613.043
1620.419
1627.795
1635.170
1642.546
1649.922
1657.297
1664.673
1672.048
1679.424
1686.800
1694.175
1701.551
1708.926
1716.302
1723.677
1731.053
1738.429
1745.804
1753.180
1760.555
1767.931
1775.307
1782.682
1790.058
1797.434
1804.809
1812.185
1819.560
1826.936
1834.312
1841.687
1849.063
1856.438
1863.814
1871.189
1878.565
1885.941
1893.316
1900.692
1908.068
1915.443
1922.819
1930.194
1937.570
1944.946
1952.321
1959.697
1967.072
1974.448
1981.823
1989.199
1996.575
2003.950
2011.326
2018.701
2026.077
2033.453
2040.828
2048.204
2055.580
2062.955
2070.331

1562.152
1569.528
1576.903
1584.279
1591.654
1599.030
1606.406
1613.781
1621.157
1628.532
1635.908
1643.283
1650.659
1658.035
1665.410
1672.786
1680.162
1687.537
1694.913
1702.288
1709.664
1717.040
1724.415
1731.791
1739.166
1746.542
1753.917
1761.293
1768.669
1776.044
1783.420
1790.795
1798.171
1805.547
1812.922
1820.298
1827.674
1835.049
1842.425
1849.800
1857.176
1864.552
1871.927
1879.303
1886.678
1894.054
1901.429
1908.805
1916.181
1923.556
1930.932
1938.307
1945.683
1953.059
1960.434
1967.810
1975.186
1982.561
1989.937
1997.312
2004.688
2012.063
2019.439
2026.815
2034.190
2041.566
2048.941
2056.317
2063.693
2071.068

1562.889
1570.265
1577.641
1585.016
1592.392
1599.768
1607.143
1614.519
1621.894
1629.270
1636.646
1644.021
1651.397
1658.772
1666.148
1673.523
1680.899
1688.275
1695.650
1703.026
1710.401
1717.777
1725.153
1732.528
1739.904
1747.280
1754.655
1762.031
1769.406
1776.782
1784.157
1791.533
1798.909
1806.284
1813.660
1821.035
1828.411
1835.787
1843.162
1850.538
1857.914
1865.289
1872.665
1880.040
1887.416
1894.792
1902.167
1909.543
1916.918
1924.294
1931.669
1939.045
1946.421
1953.796
1961.172
1968.547
1975.923
1983.299
1990.674
1998.050
2005.426
2012.801
2020.177
2027.552
2034.928
2042.303
2049.679
2057.055
2064.430
2071.806

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 21

Nm

2810
2820
2830
2840
2850
2860
2870
2880
2890
2900
2910
2920
2930
2940
2950
2960
2970
2980
2990
3000
3010
3020
3030
3040
3050
3060
3070
3080
3090
3100
3110
3120
3130
3140
3150
3160
3170
3180
3190
3200
3210
3220
3230
3240
3250
3260
3270
3280
3290
3300
3310
3320
3330
3340
3350
3360
3370
3380
3390
3400
3410
3420
3430
3440
3450
3460
3470
3480
3490
3500

2072.543
2079.919
2087.295
2094.670
2102.046
2109.421
2116.797
2124.173
2131.548
2138.924
2146.299
2153.675
2161.051
2168.426
2175.802
2183.177
2190.553
2197.929
2205.304
2212.680
2220.055
2227.431
2234.807
2242.182
2249.558
2256.933
2264.309
2271.685
2279.060
2286.436
2293.811
2301.187
2308.562
2315.938
2323.314
2330.689
2338.065
2345.441
2352.816
2360.192
2367.567
2374.943
2382.319
2389.694
2397.070
2404.445
2411.821
2419.197
2426.572
2433.948
2441.323
2448.699
2456.075
2463.450
2470.826
2478.201
2485.577
2492.953
2500.328
2507.704
2515.079
2522.455
2529.831
2537.206
2544.582
2551.957
2559.333
2566.708
2574.084
2581.460

2073.281
2080.656
2088.032
2095.408
2102.783
2110.159
2117.535
2124.910
2132.286
2139.661
2147.037
2154.413
2161.788
2169.164
2176.539
2183.915
2191.291
2198.666
2206.042
2213.417
2220.793
2228.168
2235.544
2242.920
2250.295
2257.671
2265.047
2272.422
2279.798
2287.173
2294.549
2301.925
2309.300
2316.676
2324.051
2331.427
2338.802
2346.178
2353.554
2360.929
2368.305
2375.681
2383.056
2390.432
2397.807
2405.183
2412.559
2419.934
2427.310
2434.685
2442.061
2449.437
2456.812
2464.188
2471.563
2478.939
2486.314
2493.690
2501.066
2508.441
2515.817
2523.193
2530.568
2537.944
2545.319
2552.695
2560.071
2567.446
2574.822
2582.197

2074.019
2081.394
2088.770
2096.145
2103.521
2110.896
2118.272
2125.648
2133.023
2140.399
2147.774
2155.150
2162.526
2169.901
2177.277
2184.653
2192.028
2199.404
2006.779
2214.155
2221.531
2228.906
2236.282
2243.657
2251.033
2258.408
2265.784
2273.160
2280.535
2287.911
2295.287
2302.662
2310.038
2317.413
2324.789
2332.165
2339.540
2346.916
2354.291
2361.667
2369.042
2376.418
2383.794
2391.169
2398.545
2405.920
2413.296
2420.672
2428.047
2435.423
2442.799
2450.174
2457.550
2464.925
2472.301
2479.677
2487.052
2494.428
2501.803
2509.179
2516.554
2523.930
2531.306
2538.681
2546.057
2553.433
2560.808
2568.184
2575.559
2582.935

2074.756
2082.132
2089.507
2096.883
2104.259
2111.634
2119.010
2126.385
2133.761
2141.136
2148.512
2155.888
2163.263
2170.639
2178.014
2185.390
2192.766
2200.141
2207.517
2214.893
2222.268
2229.644
2237.019
2244.395
2251.771
2259.146
2266.522
2273.897
2281.273
2288.648
2296.024
2303.400
2310.775
2318.151
2325.526
2332.902
2340.278
2347.653
2355.029
2362.405
2369.780
2377.156
2384.531
2391.907
2399.282
2406.658
2414.034
2421.409
2428.785
2436.160
2443.536
2450.912
2458.287
2465.663
2473.039
2480.414
2487.790
2495.165
2502.541
2509.917
2517.292
2524.668
2532.043
2539.419
2546.794
2554.170
2561.546
2568.921
2576.297
2583.672

2075.494
2082.869
2090.245
2097.620
2104.996
2112.372
2119.747
2127.123
2134.499
2141.874
2149.250
2156.625
2164.001
2171.376
2178.752
2186.128
2193.503
2200.879
2208.254
2215.630
2223.006
2230.381
2237.757
2245.132
2252.508
2259.884
2267.259
2274.635
2282.010
2289.386
2296.762
2304.137
2311.513
2318.888
2326.264
2333.640
2341.015
2348.391
2355.766
2363.142
2370.518
2377.893
2385.269
2392.645
2400.020
2407.396
2414.771
2422.147
2429.522
2436.898
2444.274
2451.649
2459.025
2466.400
2473.776
2481.152
2488.527
2495.903
2503.278
2510.654
2518.030
2525.405
2532.781
2540.156
2547.532
2554.908
2562.283
2569.659
2577.034
2584.410

2076.231
2083.607
2090.982
2098.358
2105.734
2113.109
2120.485
2127.860
2135.236
2142.612
2149.987
2157.363
2164.738
2172.114
2179.490
2186.865
2194.241
2201.616
2208.992
2216.368
2223.743
2231.119
2238.494
2245.870
2253.246
2260.621
2267.997
2275.372
2282.748
2290.124
2297.499
2304.875
2312.250
2319.626
2327.002
2334.377
2341.753
2349.128
2356.504
2363.880
2371.255
2378.631
2386.006
2393.382
2400.758
2408.133
2415.509
2422.884
2430.260
2437.635
2445.011
2452.387
2459.762
2467.138
2474.514
2481.889
2489.265
2496.640
2504.016
2511.392
2518.767
2526.143
2533.518
2540.894
2548.270
2555.645
2563.021
2570.396
2577.772
2585.148

2076.969
2084.344
2091.720
2099.095
2106.471
2113.847
2121.222
2128.598
2135.974
2143.349
2150.725
2158.100
2165.476
2172.852
2180.227
2187.603
2194.978
2202.354
2209.729
2217.105
2224.481
2231.856
2239.232
2246.608
2253.983
2261.359
2268.734
2276.110
2283.486
2290.861
2298.237
2305.612
2312.988
2320.364
2327.739
2335.115
2342.490
2349.866
2357.241
2364.617
2371.993
2379.368
2386.744
2394.120
2401.495
2408.871
2416.246
2423.622
2430.998
2438.373
2445.749
2453.124
2460.500
2467.875
2475.251
2482.627
2490.002
2497.378
2504.754
2512.129
2519.505
2526.880
2534.256
2541.632
2549.007
2556.383
2563.758
2571.134
2578.510
2585.885

2077.706
2085.082
2092.458
2099.833
2107.209
2114.584
2121.960
2129.335
2136.711
2144.087
2151.462
2158.838
2166.214
2173.589
2180.965
2188.340
2195.716
2203.092
2210.467
2217.843
2225.218
2232.594
2239.969
2247.345
2254.721
2262.096
2269.472
2276.847
2284.223
2291.599
2298.974
2306.350
2313.726
2321.101
2328.477
2335.852
2343.228
2350.604
2357.979
2365.355
2372.730
2380.106
2387.481
2394.857
2402.233
2409.608
2416.984
2424.360
2431.735
2439.111
2446.486
2453.862
2461.238
2468.613
2475.989
2483.364
2490.740
2498.115
2505.491
2512.867
2520.242
2527.618
2534.993
2542.369
2549.745
2557.120
2564.496
2571.872
2579.247
2586.623

2078.444
2085.820
2093.195
2100.571
2107.946
2115.322
2122.698
2130.073
2137.449
2144.824
2152.200
2159.575
2166.951
2174.327
2181.702
2189.078
2196.453
2203.829
2211.205
2218.580
2225.956
2233.332
2240.707
2248.083
2255.458
2262.834
2270.209
2277.585
2284.961
2292.336
2299.712
2307.087
2314.463
2321.839
2329.214
2336.590
2343.966
2351.341
2358.717
2366.092
2373.468
2380.844
2388.219
2395.595
2402.970
2410.346
2417.721
2425.097
2432.473
2439.848
2447.224
2454.599
2461.975
2469.351
2476.726
2484.102
2491.478
2498.853
2506.229
2513.604
2520.980
2528.355
2535.731
2543.107
2550.482
2557.858
2565.233
2572.609
2579.985
2587.360

2079.181
2086.557
2093.933
2101.308
2108.684
2116.059
2123.435
2130.811
2138.186
2145.562
2152.937
2160.313
2167.689
2175.064
2182.440
2189.815
2197.191
2204.567
2211.942
2219.318
2226.693
2234.069
2241.445
2248.820
2256.196
2263.572
2270.947
2278.323
2285.698
2293.074
2300.449
2307.825
2315.201
2322.576
2329.952
2337.327
2344.703
2352.079
2359.454
2366.830
2374.205
2381.581
2388.957
2396.332
2403.708
2411.083
2418.459
2425.835
2433.210
2440.586
2447.961
2455.337
2462.713
2470.088
2477.464
2484.839
2492.215
2499.591
2506.966
2514.342
2521.718
2529.093
2536.469
2543.844
2551.220
2558.595
2565.971
2573.347
2580.722
2588.098

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 22

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Nm

3510
3520
3530
3540
3550
3560
3570
3580
3590
3600
3610
3620
3630
3640
3650
3660
3670
3680
3690
3700
3710
3720
3730
3740
3750
3760
3770
3780
3790
3800
3810
3820
3830
3840
3850
3860
3870
3880
3890
3900
3910
3920
3930
3940
3950
3960
3970
3980
3990
4000
4010
4020
4030
4040
4050
4060
4070
4080
4090
4100
4110
4120
4130
4140
4150
4160
4170
4180
4190
4200

2588.835
2596.211
2603.587
2610.962
2618.338
2625.713
2633.089
2640.465
2647.840
2655.216
2662.591
2669.967
2677.343
2684.718
2692.094
2699.469
2706.845
2714.221
2721.596
2728.972
2736.347
2743.723
2751.099
2758.474
2765.850
2773.225
2780.601
2787.977
2795.352
2802.728
2810.103
2817.479
2824.854
2832.230
2839.606
2846.981
2854.357
2861.733
2869.108
2876.484
2883.859
2891.235
2898.611
2905.986
2913.362
2920.737
2928.113
2935.489
2942.864
2950.240
2957.615
2964.991
2972.366
2979.742
2987.118
2994.493
3001.869
3009.245
3016.620
3023.996
3031.371
3038.747
3046.123
3053.498
3060.874
3068.249
3075.625
3083.000
3090.376
3097.752

2589.573
2596.948
2604.324
2611.700
2619.075
2626.451
2633.827
2641.202
2648.578
2655.953
2663.329
2670.705
2678.080
2685.456
2692.831
2700.207
2707.583
2714.958
2722.334
2729.709
2737.085
2744.460
2751.836
2759.212
2766.587
2773.963
2781.339
2788.714
2796.090
2803.465
2810.841
2818.217
2825.592
2832.968
2840.343
2847.719
2855.094
2862.470
2869.846
2877.221
2884.597
2891.973
2899.348
2906.724
2914.099
2921.475
2928.851
2936.226
2943.602
2950.977
2958.353
2965.729
2973.104
2980.480
2987.855
2995.231
3002.606
3009.982
3017.358
3024.733
3032.109
3039.485
3046.860
3054.236
3061.611
3068.987
3076.363
3083.738
3091.114
3098.489

2590.311
2597.686
2605.062
2612.437
2619.813
2627.188
2634.564
2641.940
2649.315
2656.691
2664.066
2671.442
2678.818
2686.193
2693.569
2700.945
2708.320
2715.696
2723.071
2730.447
2737.823
2745.198
2752.574
2759.949
2767.325
2774.700
2782.076
2789.452
2796.827
2804.203
2811.579
2818.954
2826.330
2833.705
2841.081
2848.457
2855.832
2863.208
2870.583
2877.959
2885.334
2892.710
2900.086
2907.461
2914.837
2922.212
2929.588
2936.964
2944.339
2951.715
2959.091
2966.466
2973.842
2981.217
2988.593
2995.969
3003.344
3010.720
3018.095
3025.471
3032.846
3040.222
3047.598
3054.973
3062.349
3069.725
3077.100
3084.476
3091.851
3099.227

2591.048
2598.424
2605.799
2613.175
2620.551
2627.926
2635.302
2642.677
2650.053
2657.428
2664.804
2672.180
2679.555
2686.931
2694.306
2701.682
2709.058
2716.433
2723.809
2731.185
2738.560
2745.936
2753.311
2760.687
2768.062
2775.438
2782.814
2790.189
2797.565
2804.940
2812.316
2819.692
2827.067
2834.443
2841.818
2849.194
2856.570
2863.945
2871.321
2878.697
2886.072
2893.448
2900.823
2908.199
2915.574
2922.950
2930.326
2937.701
2945.077
2952.452
2959.828
2967.204
2974.579
2981.955
2989.331
2996.706
3004.082
3011.457
3018.833
3026.208
3033.584
3040.960
3048.335
3055.711
3063.086
3070.462
3077.838
3085.213
3092.589
3099.964

2591.786
2599.161
2606.537
2613.912
2621.288
2628.664
2636.039
2643.415
2650.791
2658.166
2665.542
2672.917
2680.293
2687.668
2695.044
2702.420
2709.795
2717.171
2724.546
2731.922
2739.298
2746.673
2754.049
2761.424
2768.800
2776.176
2783.551
2790.927
2798.302
2805.678
2813.054
2820.429
2827.805
2835.180
2842.556
2849.932
2857.307
2864.683
2872.058
2879.434
2886.810
2894.185
2901.561
2908.937
2916.312
2923.687
2931.063
2938.439
2945.814
2953.190
2960.566
2967.941
2975.317
2982.692
2990.068
2997.444
3004.819
3012.195
3019.570
3026.946
3034.322
3041.697
3049.073
3056.448
3063.824
3071.200
3078.575
3085.951
3093.326
3100.702

2592.523
2599.899
2607.274
2614.650
2622.026
2629.401
2636.777
2644.152
2651.528
2658.904
2666.279
2673.655
2681.030
2688.406
2695.781
2703.157
2710.533
2717.908
2725.284
2732.660
2740.035
2747.411
2754.786
2762.162
2769.538
2776.913
2784.289
2791.664
2799.040
2806.416
2813.791
2821.167
2828.542
2835.918
2843.293
2850.669
2858.045
2865.420
2872.796
2880.172
2887.547
2894.923
2902.298
2909.674
2917.050
2924.425
2931.801
2939.176
2946.552
2953.927
2961.303
2968.679
2976.054
2983.430
2990.806
2998.181
3005.557
3012.932
3020.308
3027.684
3035.059
3042.435
3049.810
3057.186
3064.562
3071.937
3079.313
3086.688
3094.064
3101.439

2593.261
2600.636
2608.012
2615.387
2622.763
2630.139
2637.514
2644.890
2652.266
2659.641
2667.017
2674.392
2681.768
2689.144
2696.519
2703.895
2711.270
2718.646
2726.021
2733.397
2740.773
2748.148
2755.524
2762.900
2770.275
2777.651
2785.026
2792.402
2799.778
2807.153
2814.529
2821.904
2829.280
2836.656
2844.031
2851.407
2858.782
2866.158
2873.533
2880.909
2888.285
2895.660
2903.036
2910.412
2917.787
2925.163
2932.538
2939.914
2947.290
2954.665
2962.041
2969.416
2976.792
2984.167
2991.543
2998.919
3006.294
3013.670
3021.046
3028.421
3035.797
3043.172
3050.548
3057.924
3065.299
3072.675
3080.050
3087.426
3094.802
3102.177

2593.998
2601.374
2608.750
2616.125
2623.501
2630.876
2638.252
2645.627
2653.003
2660.379
2667.754
2675.130
2682.506
2689.881
2697.257
2704.632
2712.008
2719.384
2726.759
2734.135
2741.510
2748.886
2756.261
2763.637
2771.013
2778.388
2785.764
2793.139
2800.515
2807.891
2815.266
2822.642
2830.018
2837.393
2844.769
2852.144
2859.520
2866.896
2874.271
2881.647
2889.022
2896.398
2903.773
2911.149
2918.525
2925.900
2933.276
2940.652
2948.027
2955.403
2962.778
2970.154
2977.530
2984.905
2992.281
2999.656
3007.032
3014.407
3021.783
3029.159
3036.534
3043.910
3051.285
3058.661
3066.037
3073.412
3080.788
3088.164
3095.539
3102.915

2594.736
2602.112
2609.487
2616.863
2624.238
2631.614
2638.990
2646.365
2653.741
2661.116
2668.492
2675.867
2583.243
2690.619
2697.994
2705.370
2712.745
2720.121
2727.497
2734.872
2742.248
2749.624
2756.999
2764.375
2771.750
2779.126
2786.501
2793.877
2801.253
2808.628
2816.004
2823.379
2830.755
2838.131
2845.506
2852.882
2860.258
2867.633
2875.009
2882.384
2889.760
2897.135
2904.511
2911.887
2919.262
2926.638
2934.013
2941.389
2948.765
2956.140
2963.516
2970.891
2978.267
2985.643
2993.018
3000.394
3007.770
3015.145
3022.521
3029.896
3037.272
3044.647
3052.023
3059.399
3066.774
3074.150
3081.525
3088.901
3096.277
3103.652

2595.473
2602.849
2610.225
2617.600
2624.976
2632.351
2639.727
2647.103
2654.478
2661.854
2669.229
2676.605
2683.981
2691.356
2698.732
2706.107
2713.483
2720.859
2728.234
2735.610
2742.985
2750.361
2757.737
2765.112
2772.488
2779.864
2787.239
2794.615
2801.990
2809.366
2816.741
2824.117
2831.493
2838.868
2846.244
2853.619
2860.995
2868.371
2875.746
2883.122
2890.497
2897.873
2905.249
2912.624
2920.000
2927.375
2934.751
2942.127
2949.502
2956.878
2964.253
2971.629
2979.005
2986.380
2993.756
3001.131
3008.507
3015.883
3023.258
3030.634
3038.010
3045.385
3052.760
3060.136
3067.512
3074.887
3082.263
3089.639
3097.014
3104.390

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 23

Nm

4210
4220
4230
4240
4250
4260
4270
4280
4290
4300
4310
4320
4330
4340
4350
4360
4370
4380
4390
4400
4410
4420
4430
4440
4450
4460
4470
4480
4490
4500
4510
4520
4530
4540
4550
4560
4570
4580
4590
4600
4610
4620
4630
4640
4650
4660
4670
4680
4690
4700
4710
4720
4730
4740
4750
4760
4770
4780
4790
4800
4810
4820
4830
4840
4850
4860
4870
4880
4890
4900

3105.127
3112.503
3119.879
3127.254
3134.630
3142.005
3149.381
3156.757
3164.132
3171.508
3178.883
3186.259
3193.635
3201.010
3208.386
3215.761
3223.137
3230.512
3237.888
3245.264
3252.639
3260.015
3267.391
3274.766
3282.142
3289.517
3296.893
3304.269
3311.644
3319.020
3326.395
3333.771
3341.146
3348.522
3355.898
3363.273
3370.649
3378.025
3385.400
3392.776
3400.151
3407.527
3414.903
3422.278
3429.654
3437.029
3444.405
3451.781
3459.156
3466.532
3473.907
3481.283
3488.658
3496.034
3503.410
3510.785
3518.161
3525.537
3532.912
3540.288
3547.663
3555.039
3562.415
3569.790
3577.166
3584.541
3591.917
3599.292
3606.668
3614.044

3105.865
3113.240
3120.616
3127.992
3135.367
3142.743
3150.118
3157.494
3164.870
3172.245
3179.621
3186.997
3194.372
3201.748
3209.123
3216.499
3223.875
3231.250
3238.626
3246.001
3253.377
3260.752
3268.128
3275.504
3282.879
3290.255
3297.631
3305.006
3312.382
3319.757
3327.133
3334.509
3341.884
3349.260
3356.635
3364.011
3371.386
3378.762
3386.138
3393.513
3400.889
3408.264
3415.640
3423.016
3430.391
3437.767
3445.143
3452.518
3459.894
3467.269
3474.645
3482.021
3489.396
3496.772
3504.147
3511.523
3518.898
3526.274
3533.650
3541.025
3548.401
3555.777
3463.152
3570.528
3577.903
3585.279
3592.655
3600.030
3607.406
3614.781

3106.603
3113.978
3121.354
3128.729
3136.105
3143.480
3150.856
3158.232
3165.607
3172.983
3180.358
3187.734
3195.110
3202.485
3209.861
3217.237
3224.612
3231.988
3239.363
3246.739
3254.115
3261.490
3268.866
3276.241
3283.617
3290.992
3298.368
3305.744
3313.119
3320.495
3327.870
3335.246
3342.622
3349.997
3357.373
3364.749
3372.124
3379.500
3386.875
3394.251
3401.626
3409.002
3416.378
3423.753
3431.129
3438.504
3445.880
3453.256
3460.631
3468.007
3475.383
3482.758
3490.134
3497.509
3504.885
3512.260
3519.636
3527.012
3534.387
3541.763
3549.138
3556.514
3563.890
3571.265
3578.641
3586.016
3593.392
3600.768
3608.143
3615.519

3107.340
3114.716
3122.091
3129.467
3136.843
3144.218
3151.594
3158.969
3166.345
3173.720
3181.096
3188.472
3195.847
3203.223
3210.598
3217.974
3225.350
3232.725
3240.101
3247.477
3254.852
3262.228
3269.603
3276.979
3284.354
3291.730
3299.106
3306.481
3313.857
3321.232
3328.608
3335.984
3343.359
3350.735
3358.110
3365.486
3372.862
3380.237
3387.613
3394.989
3402.364
3409.740
3417.115
3424.491
3431.866
3439.242
3446.618
3453.993
3461.369
3468.744
3476.120
3483.496
3490.871
3498.247
3505.622
3512.998
3520.374
3527.749
3535.125
3542.500
3549.876
3557.252
3564.627
3572.003
3579.378
3586.754
3594.130
3601.505
3608.881
3616.256

3108.078
3115.453
3122.829
3130.204
3137.580
3144.956
3152.331
3159.707
3167.083
3174.458
3181.833
3189.209
3196.585
3203.960
3211.336
3218.712
3226.087
3233.463
3240.838
3248.214
3255.590
3262.965
3270.341
3277.716
3285.092
3292.468
3299.843
3307.219
3314.594
3321.970
3329.346
3336.721
3344.097
3351.472
3358.848
3366.224
3373.599
3380.975
3388.350
3395.726
3403.102
3410.477
3417.853
3425.229
3432.604
3439.979
3447.355
3454.731
3462.106
3469.482
3476.858
3484.233
3491.609
3498.984
3506.360
3513.736
3521.111
3528.487
3535.862
3543.238
3550.614
3557.989
3565.365
3572.740
3580.116
3587.492
3594.867
3602.243
3609.618
3616.994

3108.815
3116.191
3123.566
3130.942
3138.318
3145.693
3153.069
3160.444
3167.820
3175.196
3182.571
3189.947
3197.322
3204.698
3212.073
3219.449
3226.825
3234.200
3241.576
3248.952
3256.327
3263.703
3271.078
3278.454
3285.830
3293.205
3300.581
3307.956
3315.332
3322.708
3330.083
3337.459
3344.834
3352.210
3359.585
3366.961
3374.337
3381.712
3389.088
3396.464
3403.839
3411.215
3418.590
3425.966
3433.342
3440.717
3448.093
3455.468
3462.844
3470.219
3477.595
3484.971
3492.346
3499.722
3507.098
3514.473
3521.849
3529.224
3536.600
3543.976
3551.351
3558.727
3566.102
3573.478
3580.854
3588.229
3595.605
3602.980
3610.356
3617.731

3109.553
3116.928
3124.304
3131.679
3139.055
3146.431
3153.806
3161.182
3168.558
3175.933
3183.309
3190.684
3198.060
3205.436
3212.811
3220.187
3227.562
3234.938
3242.313
3249.689
3257.065
3264.440
3271.816
3279.191
3286.567
3293.943
3301.318
3308.694
3316.070
3323.445
3330.821
3338.196
3345.572
3352.948
3360.323
3367.699
3375.074
3382.450
3389.825
3397.201
3404.577
3411.952
3419.328
3426.704
3434.079
3441.455
3448.830
3456.206
3463.582
3470.957
3478.333
3485.708
3493.084
3500.459
3507.835
3515.211
3522.586
3529.962
3537.337
3544.713
3552.089
3559.464
3566.840
3574.216
3581.591
3588.967
3596.342
3603.718
3611.094
3618.469

3110.290
3117.666
3125.042
3132.417
3139.793
3147.168
3154.544
3161.919
3169.295
3176.671
3184.046
3191.422
3198.798
3206.173
3213.549
3220.924
3228.300
3235.676
3243.051
3250.427
3257.802
3265.178
3272.553
3279.929
3287.305
3294.680
3302.056
3309.431
3316.807
3324.183
3331.558
3338.934
3346.310
3353.685
3361.061
3368.436
3375.812
3383.187
3390.563
3397.939
3405.314
3412.690
3420.065
3427.441
3434.817
3442.192
3449.568
3456.943
3464.319
3471.695
3479.070
3486.446
3493.822
3501.197
3508.573
3515.948
3523.324
3530.699
3538.075
3545.451
3552.826
3560.202
3567.577
3574.953
3582.329
3589.704
3597.080
3604.456
3611.831
3619.207

3111.028
3118.404
3125.779
3133.155
3140.530
3147.906
3155.281
3162.657
3170.033
3177.408
3184.784
3192.159
3199.535
3206.911
3214.286
3221.662
3229.037
3236.413
3243.789
3251.164
3258.540
3265.916
3273.291
3280.667
3288.042
3295.418
3302.793
3310.169
3317.545
3324.920
3332.296
3339.671
3347.047
3354.423
3361.798
3369.174
3376.550
3383.925
3391.301
3398.676
3406.052
3413.427
3420.803
3428.179
3435.554
3442.930
3450.305
3457.681
3465.057
3472.432
3479.808
3487.183
3494.559
3501.935
3509.310
3516.686
3524.062
3531.437
3538.813
3546.188
3553.564
3560.939
3568.315
3575.691
3583.066
3590.442
3597.817
3605.193
3612.569
3619.944

3111.765
3119.141
3126.517
3133.892
3141.268
3148.643
3156.019
3163.395
3170.770
3178.146
3185.521
3192.897
3200.273
3207.648
3215.024
3222.399
3229.775
3237.151
3244.526
3251.902
3259.277
3266.653
3274.029
3281.404
3288.780
3296.156
3303.531
3310.906
3318.282
3325.658
3333.033
3340.409
3347.785
3355.160
3362.536
3369.911
3377.287
3384.663
3392.038
3399.414
3406.789
3414.165
3421.541
3428.916
3436.292
3443.667
3451.043
3458.419
3465.794
3473.170
3480.545
3487.921
3495.297
3502.672
3510.048
3517.423
3524.799
3532.175
3539.550
3546.926
3554.302
3561.677
3569.052
3576.428
3583.804
3591.179
3598.555
3605.931
3613.306
3620.682

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 24

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Nm

4910
4920
4930
4940
4950
4960
4970
4980
4990
5000

3621.419
3628.795
3636.171
3643.546
3650.922
3658.297
3665.673
3673.049
3680.424
3687.800

3622.157
3629.532
3636.908
3644.284
3651.659
3659.035
3666.410
3673.786
3681.162
3688.537

3622.895
3630.270
3637.646
3645.021
3652.397
3659.772
3667.148
3674.524
3681.899
3689.275

3623.632
3631.008
3638.383
3645.759
3653.135
3660.510
3667.886
3675.261
3682.637
3690.012

3624.370
3631.745
3639.121
3646.496
3653.872
3661.248
3668.623
3675.999
3683.374
3690.750

3625.107
3632.483
3639.858
3647.234
3654.610
3661.985
3669.361
3676.736
3684.112
3691.488

3625.845
3633.220
3640.596
3647.971
3655.347
3662.723
3670.098
3677.474
3684.850
3692.225

3626.582
3633.958
3641.333
3648.709
3656.085
3663.460
3670.836
3678.211
3685.587
3692.963

3627.320
3634.695
3642.071
3649.447
3656.822
3664.198
3671.573
3678.949
3686.325
3693.700

3628.057
3635.433
3642.809
3650.184
3657.560
3664.935
3672.311
3679.687
3687.062
3694.438

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 25

Conversions Tables Part 2

40000208-en

Conversion table for units of pressure in gases, steam and fluids


Pa
1 Pa (=1N/m)

bar

at

atm
-4

Torr

0.102 x 10

1
(0 1000
mbar)

10200

1.02

0.987

750

9.81

9.81 x 10-5

10-4

0.968 x 10-4

0.0736

1at (=1kp/cm)

98100

0.981

10000

0.968

736

1 atm (= 760 Torr)

101325

1.013
(=
1013mbar)

10330

1.033

760

1 Torr (1/760 atm)

133

0.00133

13.6

0.00136

0.00132

1 kp/m

100000 = 10

0987 x 10

-5

0.102

1 bar (=0.1 Mpa)

10

kp/m

-5

0.0075

Conversion table for units of power, energy and heat quantity


J
1J (= 1Nm = 1Ws)
1kJ

kJ

kWh

0.001

kcal

2.78 x 10

-7
-4

PSh
-4

kpm

3.77 x 10

-7

0.102

0.239

3.77 x 10

-4

102

2.39 10

1000

2.78 x 10

1kWh

3600000

3600

860

1.36

367000

1kcal

4200

4.2

0.00116

0.00158

427

1PSh

2650000

2650

0.736

632

270000

1kpm

9.81

0.00981

2.72 x 10

-6

0.00234

3.7 x 10

-6

Conversion table for units of mechanical stress


Pa
1Pa (= 1N/m)

N/mm
-6

daN/cm

daN/mm

kp/cm

0.102 x 10-6

1N/mm (= 1Mpa)

1000000

10

0.1

10.2

0.102

1daN/cm (= 1bar)

100000

0.1

0.01

1.02

0.0120

10000000

10

100

102

1.02

98100

0.0981

0.981

0.00981

0.001

9810000

9.81

98.1

0.981

100

1kp/mm

0.102 x 10

kp/mm
-4

10

1kp/cm (= 1at)

10

-7

1daN/mm (= 1hbar)

10

-5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 26

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Practically equivalent units for pressure and mechanical stress (strength)


1N = 0.1kp

1kp = 10N 0 1daN

1daN/mm

1daN/cm

1kN/cm

1kp/mm

1kp/cm

= 1kp/mm
= 1kN/cm
= 1hbar

1kp/cm
1at
= 1 bar

= 1daN/mm
= 1hbar
1kp/mm 2

1daN/mm
1kN/cm
1hbar

= 1at
1daN/cm
1bar

1kbar

1hbar

1bar

1mbar

1bar

= 1hN/mm
= 10kN/cm
= 1Mp/cm

= 1daN/mm
= 1kN/cm
1kp/mm

= 1daN/cm
1kp/cm
1at

= 1cN/cm
1p/cm

= 1dN/m
1kp/m
100

Units of temperature and conversion formulars


Einheiten

Umrechnung in

Benennung
Kurzzeichen

Kelvin (K)

(K-273.16)

4/5(K-273.16)

9/5(K-273.16)+32

C + 273.16

4/5C

9/5C+32

Raumur (R)

5/4R + 273.16

5/4R

9/4R+32

Fahrenheit (F)

5/9(F-32) + 273.16

5/9(F-32)

4/9(F-32)

Celsius (C)

Example:
conversion from

R in C:

C=5/4R

The fundamental temperature unit is the Kelvin (K).


The symbol used is the T.
The equally used Rankine temperature scale for absolute temperaturs is related to K as follows:
Rank = 9/5K

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 27

Power, Energy and heat flow


1Nm/s

= 1/9.81 kpm/s = 0.102 kpm/s

1kpm/s

= 3600 kpm/h = 1/3600 kpm/s


W

1W (=1Nm/s = 1J/S)

kW

kcal/s
-4

kcal/h

kpm/s

PS

HP

0.001

2.39 x 10

0.860

0.102

0.00136

0.00134

1 kW

1000

0.239

860

102

1.36

1.341

1 kcal/s

4190

4.19

3600

427

5.69

5.61

1 kcal/h

1.16

0.00116

1/3600

0.119

0.00158

0.00156

1 kpm/s

9.81

0.00981

0.00234

8.43

0.0133

0.0131

1PS

736

0.736

0.176

632

75

0.9863

1HP

746

0.746

0.178

641.8

76.09

1.0145

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 28

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Speed
1 km/h

0.27778 m/s

1 m/s

3.6km/h

1 mile/h

1.60934 km/h

1 km/h

0.62137 mile/h

1 kn (Knoten)

1.852 km/h

1 km/h

0.53996 kn

1 ft/min

0.3048 m/min

1 m/min

3.28084 ft/min

km/h

m/s

km/h

mile/h
(mph)

kn

ft/min

km/h

mile/h
(mph)

km/h

in
m/s

in
km/h

in
mile/h

in
km/h

in
km/h

in
m/min

in
Zeit/km

in
Zeit/km

in
Zeit/100km

10
20
30
40

2.78
5.56
8.33
11.1

36.0
72.0
108
144

6.21
12.4
18.6
24.9

16.1
32.2
48.3
64.4

18.52
37.04
55.56
74.08

3.05
6.10
9.14
12.2

6 min
3 min
2 min
1 min 30 s

3 min 44 s
1 min 52 s
1 min 15 s
55.9 s

10 h
5h
3 h 20 min
2 h 30 min

50
60
70
80
90

13.9
16.7
19.4
22.2
25.0

180
216
252
288
324

31.1
37.3
43.5
49.7
55.9

80.5
96.6
113
129
145

92.60
111
130
148
167

15.2
18.3
21.3
24.4
27.4

1 min 12 s
1 min
51.4 s
45 s
40 s

44.7 s
37.3 s
32.0 s
28.0 s
24.9 s

2h
1 h 40 min
1 h 26 min
1 h 15 min
1 h 6.7 min

100
110
120
130
140

27.8
30.6
33.4
36.1
38.9

360
396
432
468
504

62.1
68.4
74.6
80.8
87.0

161
177
193
209
225

185
---------

30.5
33.5
36.6
39.6
42.7

36 s
32.7 s
30 s
27.7 s
25.7 s

22.0 s
20.3 s
18.6 s
17.2 s
16.0 s

1h
54 min 33 s
50 min
46 min 9 s
42 min 51s

150
160
170
180
190

41.7
44.4
47.2
50.0
52.8

540
576
612
648
684

93.2
99.4
106
112
118

241
257
274
290
306

-----------

45.7
48.8
51.8
54.9
57.9

24 s
22.5 s
21.2 s
20.0 s
18.9 s

14.9 s
14.0 s
13.2 s
12.4 s
11.8 s

40 min
37 min 30 s
35 min 18 s
33 min 20 s
31 min 35 s

200
250
300
400
500

55.6
59.4
83.3
111
139

720
900
1080
1440
1800

124
155
186
249
311

322
402
483
644
805

-----------

61.0
76.2
91.4
122
152

18 s
14.4 s
12 s
9s
7.2 s

11.2 s
8.9 s
7.5 s
5.8 s
4.5 s

30 min
26 min
20 min
15 min
12 min

600
800
1000
1200
1400

167
222
278
333
389

2160
2880
3600
1) -----

373
497
621
746
870

966
1287
1609
-----

-----------

183
244
305
366
427

6s
4.5 s
3.6 s
3s
2.6 s

3.7 s
2.8 s
2.2 s
-----

10 min
7 min 30 s
6 min
5 min
4 min 17 s

The Mach number "Ma" (no official unit of measurement) gives the factor by which a body is faster, than the
speed of sound.
Thus "Ma" = 1.3 means 1.3 times as fast as the speed of sound.
1) Approximate velocity of sound in the air.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 29

Units of mass (weight)


grain

dram

oz

lb

long cwt

sh cwt

long tn

sh tn

in g

in g

in g

in kg

in kg

in kg

in t

in t

1.0
1.1
1.2
1.3
1.4

0.0648
0.0713
0.0778
0.0842
0.0907

1.77
1.95
2.13
2.30
2.48

28.3
31.2
34.0
36.9
39.7

0.454
0.499
0.544
0.590
0.635

50.8
55.9
61.0
66.0
71.1

45.4
49.9
54.4
59.0
63.5

1.02
1.12
1.22
1.32
1.42

0.907
0.998
1.09
1.18
1.27

1.5
1.6
1.7
1.8
1.9

0.0972
0.104
0.110
0.117
0.123

2.66
2.83
3.01
3.19
3.37

42.5
45.4
48.2
51.0
53.9

0.680
0.726
0.771
0.816
0.862

76.2
81.3
86.4
91.4
96.5

68.0
72.6
77.1
81.6
82.2

1.52
1.63
1.73
1.83
1.93

1.36
1.45
1.54
1.63
1.72

2.0
2.1
2.2
2.3
2.4

0.130
0.136
0.143
0.149
0.156

3.54
3.72
3.90
4.08
4.25

56.7
59.5
62.4
65.2
68.0

0.907
0.953
0.998
1.04
1.09

102
107
112
117
122

90.7
95.3
99.8
104
109

2.03
2.13
2.24
2.34
2.44

1.81
1.91
2.00
2.09
2.18

2.5
2.6
2.7
2.8
2.9

0.162
0.168
0.175
0.181
0.188

4.43
4.61
4.78
4.96
5.14

70.9
73.7
76.5
79.4
82.2

1.13
1.18
1.22
1.27
1.32

127
132
137
142
147

113
118
122
127
132

2.54
2.64
2.74
2.84
2.95

2.27
2.36
2.45
2.54
2.63

3.0
3.2
3.4
3.6
3.8

0.194
0.207
0.220
0.233
0.246

5.32
5.67
6.02
6.38
6.73

85.0
90.7
96.4
102
108

1.36
1.45
1.54
1.63
1.72

152
163
173
183
193

136
145
154
163
172

3.05
3.25
3.45
3.66
3.86

2.72
2.90
3.08
3.27
3.45

4.0
4.2
4.4
4.6
4.8

0.259
0.272
0.285
0.298
0.311

7.09
7.44
7.80
8.15
8.50

113
119
125
130
136

1.81
1.91
2.00
2.09
2.18

203
213
224
234
244

181
191
200
209
218

4.06
4.27
4.47
4.67
4.88

3.63
3.81
3.99
4.17
4.35

5.0
5.2
5.4
5.6
5.8

0.324
0.337
0.350
0.363
0.376

8.86
9.21
9.57
9.92
10.3

142
147
153
159
164

2.27
2.36
2.45
2.54
2.63

254
264
274
284
295

227
236
245
254
263

5.08
5.28
5.49
5.69
5.89

4.54
4.72
4.90
5.08
5.26

6.0
6.5
7.0
7.5

0.389
0.421
0.454
0.486

10.6
11.5
12.4
13.3

170
184
198
213

2.72
2.95
3.18
3.40

305
330
356
381

272
295
318
340

6.10
6.60
7.11
7.62

5.44
5.90
6.35
6.80

8.0
8.5
9.0
9.5

0.518
0.551
0.583
0.616

14.2
15.1
15.9
16.8

227
241
255
269

3.63
3.86
4.08
4.31

406
432
457
483

363
386
408
431

8.13
8.64
9.14
9.65

7.26
7.71
8.16
8.62

The table is also valid for decimal multiples and fractions.


Example: 1 lb = 0.454 kg; 5 long ton = 5.08 t; 42 oz = 1190 g.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 30

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Units of volume, flow rates


in

ft

yd

pt
(UK)

liq pt gal
(US)
(UK)

gal
(US)

ft/min
cfm

in
cm

in
l

in
m

in
l

in
l

in
l

in
l

in
m/h

1.0
1.1
1.2
1.3
1.4

16.4
18.0
19.7
21.3
22.9

28.3
31.2
34.0
36.8
39.6

0.765
0.841
0.918
0.994
1.07

0.568
0.625
0.682
0.739
0.796

0.473
0.520
0.568
0.615
0.662

4.55
5.00
5.46
5.91
6.36

3.79
4.16
4.54
4.92
5.30

1.70
1.87
2.04
2.21
2.38

1.5
1.6
1.7
1.8
1.9

24.6
26.2
27.9
29.5
31.1

42.5
45.3
48.1
51.0
53.8

1.15
1.22
1.30
1.38
1.45

0.852
0.909
0.966
1.02
1.08

0.710
0.757
0.804
0.852
0.899

6.82
7.27
7.73
8.18
8.64

5.68
6.06
6.44
6.81
7.19

2.55
2.72
2.89
3.06
3.23

2.0
2.1
2.2
2.3
2.4

32.8
34.4
36.1
37.7
39.3

56.6
59.5
62.3
65.1
68.0

1.53
1.61
1.68
1.76
1.83

1.14
1.19
1.25
1.31
1.36

0.946
0.994
1.04
1.09
1.14

9.09
9.55
10.0
10.5
10.9

7.57
7.95
8.33
8.71
9.09

3.40
3.57
3.74
3.91
4.08

2.5
2.6
2.7
2.8
2.9

41.0
42.6
44.3
45.9
47.5

70.8
73.6
76.5
79.3
82.1

1.91
1.99
2.06
2.14
2.22

1.42
1.48
1.53
1.59
1.65

1.18
1.23
1.28
1.32
1.37

11.4
11.8
12.3
12.7
13.2

9.46
9.84
10.2
10.6
11.0

4.25
4.42
4.59
4.76
4.93

3.0
3.2
3.4
3.6
3.8

49.2
52.4
55.7
59.0
62.3

85.0
90.6
96.3
102
108

2.29
2.45
2.60
2.75
2.91

1.70
1.82
1.93
2.05
2.16

1.42
1.51
1.61
1.70
1.80

13.6
14.6
15.5
16.4
17.3

11.4
12.1
12.9
13.6
14.4

5.10
5.44
5.78
6.12
6.46

4.0
4.2
4.4
4.6
4.8

65.6
68.8
72.1
75.4
78.7

113
119
125
130
136

3.06
3.21
3.36
3.52
3.67

2.27
2.39
2.50
2.61
2.73

1.89
1.99
2.08
2.18
2.27

18.2
19.1
20.0
20.9
21.8

15.1
15.9
16.7
17.4
18.2

6.80
7.14
7.48
7.82
8.16

5.0
5.2
5.4
5.6
5.8

81.9
85.2
88.5
91.8
95.1

142
147
153
159
164

3.82
3.98
4.13
4.28
4.43

2.84
2.96
3.07
3.18
3.30

2.37
2.46
2.56
2.65
2.74

22.7
23.6
24.6
25.5
26.4

18.9
19.7
20.4
21.2
22.0

8.50
8.84
9.18
9.52
9.85

6.0
6.2
6.4
6.6
6.8

98.3
102
105
108
111

170
176
181
187
193

4.59
4.74
4.89
5.05
5.20

3.41
3.52
3.64
3.75
3.86

2.84
2.93
3.03
3.12
3.22

27.3
28.2
29.1
30.0
30.9

22.7
23.5
24.2
25.0
25.7

10.2
10.5
10.9
11.2
11.6

7.0
7.5

115
123

198
212

5.35
5.73

3.98
4.26

3.31
3.55

31.8
34.1

26.5
28.4

11.9
12.7

8.0
8.5

131
139

227
241

6.12
6.50

4.55
4.83

3.79
4.02

36.4
38.6

30.3
32.2

13.6
14.4

9.0
9.5

148
156

255
269

6.88
7.26

5.11
5.40

4.26
4.50

40.9
43.2

34.1
36.0

15.3
16.1

Example: 1 in3 = 16.4 cm3; 3 gal (UK) = 13.6 l

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 31

Fuel consumption
1 g/PSh

1.3569 g/kWh

1 g/kWh

0.7355 g/PS h

1 lb/HP H

608.277 g/kWh

1 g/kWh

0.001644 lb/HP H

1 liq pt/HP H

634.545 cm/kWh

1 cm/kWh

0.001576 liq pt/HP H

1 pt (UK)/HP H

762.049 cm/kWh

1 cm/kWh

0.001312 pt (UK)/HP H

Conversion from

Conversion from

Conversion from

g/PSh

g/kWh

lb

liq pt

pt (UK)

miles

miles

in
g/kwh

in
g/PSh

HP H

HP h

HP H

gal (US)

gal (UK)

100
120
140
160
180

136.0
163.2
190.3
217.5
244.7

73.55
88.26
103.0
117.7
132.4

0.10
0.15

60.83
91.24

63.45
95.18

76.20
114.3

0.20
0.25

121.7
152.1

126.9
158.6

152.4
190.5

10
11
12
13
14

23.5
21.4
19.6
18.1
16.8

28.2
25.7
23.5
21.7
20.2

200
220
240
260
280

271.9
299.1
326.3
353.5
380.7

147.1
161.8
176.5
191.2
205.9

0.30
0.32
0.34
0.36
0.38

182.5
194.6
206.8
219.0
231.1

190.4
203.1
215.7
228.4
241.1

228.6
243.9
259.1
274.3
289.6

15
16
17
18
19

15.7
14.7
13.8
13.1
12.4

18.8
17.7
16.6
15.7
14.9

300
320
340
360
380

407.9
435.1
462.3
489.5
516.6

220.6
235.4
250.1
264.8
279.5

0.40
0.42
0.44
0.46
0.48

243.3
255.5
276.6
279.8
292.0

253.8
266.5
279.2
291.9
304.6

304.8
320.1
335.3
350.5
365.8

20
22
24
26
28

11.8
10.7
9.80
9.05
8.40

14.1
12.8
11.8
10.9
10.1

400
420
440
460
480

543.8
571.0
598.2
625.4
652.6

294.2
308.9
323.6
338.3
353.0

0.50
0.52
0.54
0.56
0.58

304.1
316.3
328.5
340.6
352.8

317.3
330.0
342.7
355.3
368.0

381.0
396.3
411.5
426.7
442.0

30
32
34
36
38

7.84
7.35
6.92
6.53
6.19

9.42
8.83
8.31
7.85
7.43

500
520
540
560
580

679.8
707.0
734.2
761.4
788.6

367.7
382.5
397.2
411.9
426.6

0.60
0.62
0.64
0.66
0.68

365.0
377.1
389.3
401.5
413.6

380.7
393.4
406.1
418.8
431.5

457.2
472.5
487.7
503.0
518.2

40
42
44
46
48

5.89
5.60
5.35
5.11
4.90

0.06
6.73
6.42
6.14
5.88

600
650
700
750
800 900

815.8
883.7
951.7
1020
1088
1224

441.3
478.1
514.8
551.6
588.4
661.9

0.70
0.75
0.80
0.85
0.90
0.95

425.8
456.2
486.6
517.0
547.4
577.9

444.2
475.9
507.6
539.4
571.1
602.8

533.4
571.5
609.6
647.7
685.8
723.9

50
55
60
70
80
90

4.70
4.28
3.92
3.36
2.94
2.61

5.65
5.14
4.71
4.04
3.53
3.14

Example

Example

Example

240 g / PS h = 326.3 g / kW h

0.68 liq pt / HP H = 431.5 cm / kW h

18 miles / gal(US) = 13.1 l / 100 km

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 32

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Tightening Torques

40000209-en

General information
The following tables contain the tightening torques for screws with a DIN 13 - 13 metric thread.
The construction dept. may specify in certain cases tightening torques other than those set out in the standard. The values set out in the tables are therefore applicable unless otherwise specified in the "Inspection and servicing" chapter of the operating instructions, the Technical Handbook or the drawings.
The tightening torques specified do not only depend on the screw grade, but also on the friction at the thread
and the bearing face of the screw head. Therefore, different friction coefficients ( total) depending on the type
and condition of the screws used must be applied when calculating tightening torques.
1. Friction coefficient total = 0.10:
screw and/or nut electro-galvanized (surface protection A3B).
2. Friction coefficient total = 0.12:
screw black-plated or phosphatized
nut bright
thread oiled
3. Friction coefficient total = 0.16:
screws with liquid screw fixer, e.g. Loctite 242, 243, in acc. with application instructions.
The corresponding column is marked in the tables with an "L".
The three figures given are mean friction coefficients.
The calculated tightening torques MA are valid for tightening of the screws by hand.

Units of measurement
The tightening torques specified in the tables are expressed in Nm (newtonmeter). If older torque wrenches
are used for tightening, the Nm values must be converted to the formerly used kpm (kilopondmeter) unit. The
conversion is simple since 1 kpm is almost exactly the same as 10 Nm (exact coversion factor: 1 kpm = 9.81
Nm). The small difference can be ignored so that for conversion purposes the Nm value must only be divided
by 10.
Exaple:

1840 Nm =

1840
= 184kpm
10

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 33

Bolts with standard thread DIN 13 13


Thread nominal

Material quality

Tightening torques MA in Nm
total 0.10

1)

total 0.12 2)

total 0.16 (L) 3)

M5

8.8
10.9
12.9

4.9
7.3
8.5

5.5
8.1
9.5

6.5
9.5
11.2

M6

8.8
10.9
12.9

8.5
12.5
14.5

9.5
14
16.5

11.2
16.5
19.5

M8

8.8
10.9
12.9

20.5
30
35

23
34
40

27
40
47

M 10

8.8
10.9
12.9

41
60
71

46
68
79

55
80
94

M 12

8.8
10.9
12.9

71
104
195

79
117
215

94
140
260

M 16

8.8
10.9
12.9

170
250
300

195
280
330

230
340
400

M 20

8.8
10.9
12.9

350
490
580

390
560
650

470
670
780

M 24

8.8
10.9
12.9

600
850
1000

670
960
1120

800
1140
1350

M 30

8.8
10.9
12.9

1190
1700
2000

1350
1900
2250

1600
2300
2700

M 36

8.8
10.9
12.9

2100
3000
3500

2350
3300
3900

2800
4000
4700

1)

Screw and/or nut electro-galvanized.

2)

Screw black-plated or phosphatized, thread oiled.

3)

Screws with liquid screw fixer, e.g. Loctite 242, 243.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 34

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Bolts with metric fine thread DIN 13 13


Thread nominal

Material quality

Tightening torques MA in Nm
total 0.10

1)

total 0.12 2)

total 0.16 (L) 3)

M 8x1

8.8
10.9
12.9

22
32
38

24.5
36
43

30
43
51

M 10x1

8.8
10.9
12.9

45
67
78

52
76
89

62
91
107

M 10x1.25

8.8
10.9
12.9

43
64
74

49
72
84

58
86
100

M 12x1.25

8.8
10.9
12.9

77
112
130

87
125
150

104
150
180

M 14x1.5

8.8
10.9
12.9

121
175
205

135
200
235

165
240
280

M 16x1.5

8.8
10.9
12.9

180
270
310

205
300
360

250
370
430

M 20x1.5

8.8
10.9
12.9

380
540
630

430
620
720

530
750
880

M 22x1.5

8.8
10.9
12.9

510
720

580
820
960

700
1000
1170

M 24x2

8.8
10.9
12.9

640
920
1070

730
1040
1220

890
1250
1500

M 27x2

8.8
10.9
12.9

940
1350
1550

1070
1500
1800

1300
1850
2150

M 30x2

8.8
10.9
12.9

1370
1940
2270

1490
2120
2480

1740
2480
2900

1)

Screw and/or nut electro-galvanized.

2)

Screw black-plated or phosphatized, thread oiled.

3)

Screws with liquid screw fixer, e.g. Loctite 242, 243.

840

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

Tightening torques for SAE flange system

1 - 35

Tightening angles

Fig. 2
Fig. 1

Tighten bolts in several stages. 1)


Sequence:
1)

1, 2, 3, 4

See Fittings, pipes and hoses

min

30

min

45

7.5

min

60

10

min

90

15

min

135

22.5

min

220

36.7

min

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 36

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Calculation Examples
40000210-en

Angles of Slope

Fig. 3

Travel Speed

V=

360
t

= km/h

= seconds needed for 100m

Example: At a constant speed, a travel time of 18 seconds is needed for a distance of 100 meters.

V( km / h ) =

360
= 20km / h
18

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

1 - 37

Hydraulic outputs (pumps/motors)

P=

p Q
600

=kW

=bar

=l/min

Example: For a pump with an effective discharge rate of Q = 80 l/min, at a pressure of p = 300 bar the output
is to be calculated.

P( kW ) =

300 80
= 40kW
600

Stroking times of cylinders

t=

VZyl . 60
Qp

= Seconds

VZyl.

= Volume of the cylinder(s) in dm

Qp

= theoretical discharge rate of the pump(s) in l/min

Example: For a given pump discharge rate of Qp = 80 l/min and a cylinder


volume of VZyl. = 10 dm we obtain.

t ( Sek ) =

10 60
= 7.5 sec
80

Speeds of hydraulic motors

n=

Vp np
VM

= motor speed in rpm

Vp

= geometrical displacement of the pump in cm /revolution

np

= turning speed of the pump in rpm

VM

= geometrical displacement of the motor in cm/rpm

Example: For a given pump speed np = 2.150 rpm, a geometrical displacement of the
pump Vp = 11 cm /rpm and a geometrical dis-placement of the motor of VM = 8 cm /rpm we obtain.

n=

11 2150
= 2956 min 1
8

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 38

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Special tools for cylinders

40000248-en

Screwed hex insert for piston nut

Scraper ring Assembly

Fig. 1

Fig. 3

85 mm

8488394

Boom cylinder

8488401

90 mm

8488393

Stick cylinder

8488403

100 mm

8488395

Bucket cylinder

8488401

110 mm

8488396

Sealing kit Assembly

Bushes - Dismantling

Fig. 4

Fig. 2

Boom cylinder

8488397

Stick cylinder

8488399

Bucket cylinder

8488398

85 mm

Boom cylinder

1494090

95 mm

Stick cylinder

1494091

75 mm

Bucket cylinder

1494092

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

Rod guide assembly

Piston nut loosening and tightening

Fig. 5

Fig. 6

Boom cylinder

8488409

Stick cylinder

8488410

Bucket cylinder

8488409

All cylinders

1 - 39

75298623

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 40

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Special tools for axles and gearboxes

40000280-en

Axial stress meter

Driving tool for bushing

Fig. 1

Fig. 4

Part number

2897001

Part number

2897004

Bearing friction moment adjusting device

Assembly aid for shaft seals

Fig. 2

Fig. 5

Part number

2897002

Part number

Driving tool for bushing

Master shaft

Fig. 3

Fig. 6

Part number

2897003

Part number

2897005

2897006

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

Master shaft

Driving tool

Fig. 7

Fig. 10

Part number

2897007

Part number

Extraction device

Driving tool

Fig. 8

Fig. 11

Part number

2897008

Part number

Driving tool

Assembly aid

Fig. 9

Fig. 12

Part number

2897009

Part number

1 - 41

2897010

2897011

2897012

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 42

TECHNICAL DATA AND SPECIAL TOOLS

Assembly aid

Hydraulic pump

Fig. 13

Fig. 16

Part number

2897013

Part number

1424974

Brake centering device

Measuring device

Fig. 14

Fig. 17

Part number

2897014

Part number

2494917

Tool handle

Threaded studs

Fig. 15

Fig. 18

Part number

2897039

Part number

WX210 - WX240

1148413 (M12x220)
0421225 (M12X260)

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TECHNICAL DATA AND SPECIAL TOOLS

Driving tool for shaft seals

Driving tool

Fig. 19

Fig. 21

Part number

2897015

Part number

2897017

Driving tool

Fig. 20

Part number

1 - 43

2897016

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

1 - 44

TECHNICAL DATA AND SPECIAL TOOLS

WX210 - WX240

Spacers

40000249-en

Fig. 1

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

a
240
240
240
240
240
240
240
240
240
240
240
260
260
260
260
150
150
150
150
150

i
101
101
101
131
131
131
111
111
111
121
121
121
141
141
141
101
101
101
81
81

t
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2

P/N.
3024380
3024381
3024382
3024383
3024384
3024385
3032000
3032001
3032002
3032003
3032004
3032005
3032006
3032007
3032008
3032009
3032010
3032011
3032012
3032013

No.
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

a
150
150
150
150
120
120
120
130
130
130
190
190
190
190
190
190
200
200
200
200

i
81
91
91
91
71
71
71
81
81
81
91
91
91
101
101
101
121
121
121
131

t
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1

P/N
3032014
3032015
3032016
3032017
3032018
3032019
3032020
3032021
3032022
3032023
3032024
3032025
3032026
3032027
3032028
3032029
3032030
3032031
3032032
3032033

No.
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

a
200
200
220
220
220
160
160
160
120
120
120
160
160
160
180
180
180
240
240
240

i
131
131
101
101
101
71
71
71
61
61
61
61
61
61
111
111
111
151
151
151

t
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3

P/N
3032034
3032035
3032036
3032037
3032038
3032039
3032040
3032041
3032042
3032043
3032044
3032045
3032046
3032047
3033104
3033105
3033106
3033107
3033108
3033109

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

Service manual
Section 2 Machine Structure
WX210 - WX240

9-91270

2-2

MACHINE STRUCTURE

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2-3

2-4

MACHINE STRUCTURE

WX210 - WX240

Table of contents

MACHINE CONSTRUCTION ......................................................................... 5


Description of the machine (boom-adjusting equipment) .......................................................... 6
Machine layout ............................................................................................................................................... 7
Undercarriage ................................................................................................................................................ 7
Superstructure................................................................................................................................................ 7
Hydraulic system............................................................................................................................................ 7
Steering.......................................................................................................................................................... 7
Service brake ................................................................................................................................................. 7
Parking brake ................................................................................................................................................. 8
Floating axle................................................................................................................................................... 8
Electrical system ............................................................................................................................................ 8
Working equipment ........................................................................................................................................ 8

Description of the machine (monoblock boom) ........................................................................ 10


Machine layout ............................................................................................................................................. 11
Undercarriage .............................................................................................................................................. 11
Superstructure.............................................................................................................................................. 11
Hydraulic system.......................................................................................................................................... 11
Steering........................................................................................................................................................ 11
Service brake ............................................................................................................................................... 11
Parking brake ............................................................................................................................................... 12
Floating axle................................................................................................................................................. 12
Electrical system .......................................................................................................................................... 12
Working equipment ...................................................................................................................................... 12
Switches / keys ............................................................................................................................................ 14
Control elements .......................................................................................................................................... 30
Multifunction display..................................................................................................................................... 34

Superstructure components, overview ...................................................................................... 44


Engine assembly components, overview................................................................................... 45
Hydraulic system components, overview .................................................................................. 46
Drive unit components, overview................................................................................................ 47
Undercarriage components, overview ........................................................................................ 48

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

MACHINE CONSTRUCTION

2-5

40000366-en

The following chapters describe the construction of


the machine:
Overview components
Overview switches and pushbuttons
Overview control elements
Overview multifunction display
Overview superstructure components
Overview engine assembly components
Overview undercarriage components
Overview equipment components
Overview optional components

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2-6

MACHINE STRUCTURE

WX210 - WX240

Description of the machine (boom-adjusting equipment)

S0000445-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2-7

Machine layout

Undercarriage

(Legend of Fig. 1)

The undercarriage of the hydraulic excavator is


used as a stable base and for travelling.

1 - Refuelling station / optional equipment


2 - Fuel tank
3 - Hydraulic oil reservoir
4 - Hydraulic pumps
5 - Engine
6 - Counterweight

The undercarriage is moreover equipped with


components permitting stabilization of the machine
during working operations, such as the levelling
blade and the outriggers.
The machine is driven hydraulically by oil motors
and travel gearboxes acting on both axles.

7 - Combined radiator

Undercarriage and superstructure are connected


by a slewing ring.

8 - Air intake system

Superstructure

9 - Batteries

The superstructure accommodates the drive engine and part of the hydraulic and electrical systems.

10 - Slewing gearbox
11 - Rotor
12 - Backhoe bucket

The superstructure carries also the working equipment.

13 - Toggle link

Hydraulic system

14 - Toggle lever

All travelling and working movements are executed


hydraulically. The working commands are initiated
by hand and transmitted through control circuits.
The oil flow between superstructure and undercarriage is ensured by the rotor. The hydraulic system
is protected against overloading by pressure relief
valves.

15 - Bucket cylinder
16 - Stick
17 - Stick cylinder
18 - Upper boom section
19 - Boom cylinder

Steering

20 - Boom adjusting cylinder

22 - Stabilization / outriggers

The machine is equipped with a hydrostatic power


steering system, i.e it can be steered by hand with
increased force when the engine is not running or
when the hydraulic steering pump has failed.

23 - Rigid axle

Service brake

24 - Slewing ring

The service brake is composed of four multipledisk brake integrated in the wheel-hubs. The brake
is operated hydraulically.

21 - Lower boom section

25 - Tool box
26 - Access ladder
27 - Cardan shaft
28 - Steered axle

To ensure the braking function at all times, the


braking system is equipped with hydraulic pressure
accumulators which are permanently monitored.

29 - Stabilization / levelling blade


30 - Driver's cab

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2-8

MACHINE STRUCTURE

WX210 - WX240

Parking brake

Electrical system

The parking brake can be applied by blocking the


brake disks with spring pressure.

The electrical system operates on 24 volts. An


electronic voltage regulator supplies also 12 volts.
Electronic modules (Power Control System) ensure that the available engine power is converted
in the best possible way into hydraulic performance.

The parking brake is incorporated in the travel


gearbox and acts therefore on all the wheels.

Floating axle
The steered axle is a floating axle that can be
blocked hydraulically during the work with two cylinders.

Working equipment
The working equipment is composed of the boom
(lower and upper), stick, toggle link with toggle
lever and bucket. Other digging or working equipment can also be attached to the machine.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2-9

2 - 10

MACHINE STRUCTURE

WX210 - WX240

Description of the machine (monoblock boom)

S0000446-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 11

Machine layout

Undercarriage

(Legend of Fig. 1)

The undercarriage of the hydraulic excavator is


used as a stable base and for travelling.

1 - Refuelling station / optional equipment


2 - Fuel tank
3 - Hydraulic oil reservoir
4 - Hydraulic pumps
5 - Engine
6 - Counterweight

The undercarriage is moreover equipped with


components permitting stabilization of the machine
during working operations, such as the levelling
blade or outriggers.
The machine is driven hydraulically by oil motors
and travel gearboxes acting on both axles.

7 - Combined radiator

Undercarriage and superstructure are connected


by a slewing ring.

8 - Air intake system

Superstructure

9 - Batteries

The superstructure accommodates the drive engine and part of the hydraulic and electrical systems.

10 - Slewing gearbox
11 - Rotor
12 - Backhoe bucket

The superstructure carries also the working equipment.

13 - Toggle link

Hydraulic system

14 - Toggle lever

All travelling and working movements are executed


hydraulically. The working commands are initiated
by hand and transmitted through control circuits.
The oil flow between superstructure and undercarriage is ensured by the rotor. The hydraulic system
is protected against overloading by pressure relief
valves.

15 - Bucket cylinder
16 - Stick
17 - Stick cylinder
18 - Upper boom section
19 - Boom cylinder

Steering

20 - Stabilization / outriggers

22 - Slewing ring

The machine is equipped with a hydrostatic power


steering system, i.e it can be steered by hand with
increased force when the engine is not running or
when the hydraulic steering pump has failed.

23 - Tool box

Service brake

24 - Access ladder

The service brake is composed of four multipledisk brake integrated in the wheel-hubs. The brake
is operated hydraulically.

21 - Rigid axle

25 - Cardan shaft
26 - Steered axle
27 - Stabilization / levelling blade
28 - Driver's cab

To ensure the braking function at all times, the


braking system is equipped with hydraulic pressure
accumulators which are permanently monitored.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 12

MACHINE STRUCTURE

WX210 - WX240

Parking brake

Electrical system

The parking brake can be applied by blocking the


brake disks with spring pressure.

The electrical system operates on 24 volts. An


electronic voltage regulator supplies also 12 volts.
Electronic modules (Power Control System) ensure that the available engine power is converted
in the best possible way into hydraulic performance.

The parking brake is incorporated in the travel


gearbox and acts therefore on all the wheels.

Floating axle
The steered axle is a floating axle that can be
blocked hydraulically during the work with two cylinders.

Working equipment
The working equipment is composed of the boom
(lower and upper), stick, toggle link with toggle
lever and bucket. Other digging or working equipment can also be attached to the machine.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 13

2 - 14

MACHINE STRUCTURE

WX210 - WX240

Switches / keys

10000172.01-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 15

Page 1 of 8
No.

Designation

Function

Multifunction display

Control and monitoring of machine functions (detailed description, see "Multifunction display")

Rocker switch

Symbol

Shifted boom operation


Shifted boom operation
- to activate (hinged joint upper
depress switch face without symbol
boom section, optional equipment)
- to deactivate depress switch face with symbol
(see: "shifted boom operation")

Rocker switch

Hydraulic shears

Hydraulic shears

(optional equipment)

- to activate depress switch face without symbol


- to deactivate depress switch face with symbol

Rocker switch

Hydraulic rotary
cutter
(optional equipment)

Rocker switch

Hydraulic hammer
(optional equipment)

Hydraulic rotary cutter


- to activate depress switch face without symbol
- to deactivate depress switch face with symbol
- Hydraulic hammer
- to activate depress switch face without symbol
- to deactivate depress switch face with symbol

Rocker switch

Rotary beacon
(optional equipment)

- Rotary beacon
- to activate depress switch face without symbol
- to deactivate depress switch face with symbol

Key-switch

Electrical system

Activation / deactivation of electrical system, starting / stopping the engine


Activation / deactivation of part of the electrical system (P)
(Radio, cab interior lighting)

Rocker switch

Floodlamp at the
rear
(optional equipment)

- Floodlamp
- to activate depress switch face without symbol

Rocker switch

- to deactivate depress switch face with symbol

Floodlamp on cab / - Floodlamp


equipment
- to activate depress switch face without symbol
- to deactivate depress switch face with symbol

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 16

MACHINE STRUCTURE

WX210 - WX240

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 17

Page 2 of 8
No.

Designation

Function

10

Rocker button

Screen-wiper
automatic wipe /
wash function

Activates the screen-washer pump and the


wiper as long as the switch face without
symbol is kept depressed

11

Rocker switch

Screen-wiper

Screen-wiper with multistage switch


stage 0 = screen-wiper OFF
stage I = intermittent wiping
stage II = continuous wiping

Symbol

To deactivate the screen-wiper depress switch face with symbol until the
pilot lamp of the switch is off
12

Key

Engine speed control

Engine speed reduction down to idling in 7


steps (power stages see No. 13)

13

Key

Engine speed control

Engine speed increase up to max. speed


in 7 steps (7 power stages with fixed speed
levels)
Power stage 1
Power stage 2
Power stage 3
Power stage 4
Power stage 5
Power stage 5
Power stage 7

14

Key

Auto-Idle

Activation / deactivation of automatic


speed reduction.
After activation, the speed of the diesel
engine is automatically reduced to a lower
speed during no-work phases lasting longer than 6 seconds. (see "Activating / deactivating the automatic speed reduction")

15

Key

Low-Idle

Sets engine to idling speed. If Auto-Idle


and Low-Idle are on at the same time,
Low-Idle has higher priority.

12-15 Keypad module

C5.1C

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 18

MACHINE STRUCTURE

WX210 - WX240

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 19

Page 3 of 8
No.
16

Designation
Key

Function
Gearshift

Symbol

Manual gearshift:
Key equipped with 2 LEDs
1st gear: LED1 on
2nd gear: LED2 on
last state stored when "ignition off"
Shift during driving:
1st -> 2nd gear below 3 km/h
2nd -> 1st gear below 1 km/h
Shift request registerd above the limit
speeds (corresponding LED on), shift request executed on reaching of the shifting
condition

17

Key

Superstructure
holding brake

The key is equipped with 2 LEDs


LED1 and LED2 = off
holding brake released, superstructure free
to turn
LED1 = on
holding brake applied, superstructure braked
LED2 = on
automatic mode, holding brake is applied
and released automatically, exact braking
in difficult working conditions, see: "Applying / releasing the superstructure holding
brake")

18

Key

Overload warning
system
(optional equipment)

LED = off overload warning system off


LED1 = on overload warning system on
(machine not additionally stabilized)
LED2 = on overload warning system on
(machine additionally stabilized,
optional equipment)

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 20

MACHINE STRUCTURE

WX210 - WX240

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 21

Page 4 of 8
No.
19

Designation
Key

Function
Slewing movent
braking action

Symbol

The key is equipped with 2 LEDs


LED = off soft braking of superstructure
slewing movement
LED1 = on standard braking of super
structure slewing movement
LED1 and 2 = on
harsh braking of superstructure
slewing movement
(see: "Slewing and braking the
superstructure")

17-19 Keypad module

C5.2C

35

20

Keypad module

Fog warning lamp


lit up

Fog warning lamp


- To activate the fog warning lamp depress blank face of switch
- To deactivate the fog warning lamp depress symbol face of switch

21

Indicator lamp

22

Socket outlet

23

Potentiometer
(Inching)

Parking brake

Lit up when the parking brake is applied


12 V

Travelling speed
limitation

Inching
Adjusting of maximum travelling speed
when travel pedal is fully depressed.
Readjustment during driving possible.
To the left

-> minimum

To the right -> maximum


24

Rotary switch

Blower

Switches the blower into stages:


0 = off,1, 2, 3

25

Pushbutton/white

Air conditioner /
heating

Recirculated air on / off

26

Pushbutton /blue

Air conditioner /
heating
(optional equipment)

Air conditionder on / off


(See "Air conditioner, switching on / off")

27

Control knob

Heating

Heating performance control:


fully left min. heating performance (blue)
fully right max. heating performance (red)

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 22

MACHINE STRUCTURE

WX210 - WX240

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 23

Page 5 of 8
No.

Designation

Function

28

Rocker switch

Independent contol of stabilizers /


levelling blade
(optional equipment)

Depending on optional equipment, the


stabilizer / levelling blade is activated or
deactivated.

29

Rocker switch

Independent contol of stabilizers /


levelling blade
(optional equipment)

Depending on optional equipment, the


stabilizer / levelling blade is activated or
deactivated.

30

Rocker switch

Independent contol of stabilizers /


levelling blade
(optional equipment)

Depending on optional equipment, the


stabilizer / levelling blade is activated or
deactivated.

31

Rocker switch

Independent contol of stabilizers /


levelling blade
(optional equipment)

Depending on optional equipment, the


stabilizer / levelling blade is activated or
deactivated.

Symbol

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 24

MACHINE STRUCTURE

WX210 - WX240

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 25
Page 6 of 8

No.
32

Designation
Rocker switch

Function
Parking and service brake

Symbol

Parking and service brake


Switch equipped with 2 LEDs
3 switching states
1. brake permanently blocked: LED1 on,
2. brake permanently blocked: LED1 off
3. automatic mode (active only in 1st
gear ! ): LED2 on
Brake is released when:
- travel pedal is being depressed

33

Key

Floating axle
blocking

Floating axle blocking


Key equipped with 2 LEDs
3 switching states
1. permanently blocked:

LED1 off

2. permanently released:

LED2 on

3. automatic mode:

LED2 on

last state stored when "ignition off" Automatic mode ON - OFF: depress key > 2
sec
Automatic mode:
Axle is unblocked, when:
- travel pedal is depressed and excavator
starts rolling or
- stabilizers are being moved
Attention: axle is unblocked only if safety
lever (72) in in lower position !

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 26

MACHINE STRUCTURE

WX210 - WX240

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 27

Page 7 of 8
No.

Designation

Function

35

Key

Road travel

To activate the road travel mode:


Set safety lever (72, Fig. 2 in "Control elements") to position 0 (see Fig. 1 "Starting
the engine") / (electro-hydraulic pilot control = OFF)
depress symbol face of key; LED2 lights
up.
To deactivate the road travel mode:
Set safety lever (72, Fig. 2 in "Control elements") to position 0
depress symbol face of key;
LED2 is off.

36

Key

Creep speed

To activate creep speed depress symbol face of key;


LED2 and the symbol light up
To deactivate creep speed depress symbol face of key;
LED2 and the are off

16/32, Keypad module


33/36

Symbol

C5.3

37

Multifunction lever Lighting


(steering column)

Lighting OFF

38

Multifunction lever Lighting


(steering column)

Sidemarker lights ON

39

Multifunction lever Lighting


(steering column)

Dipped beam ON

40

Multifunction lever Signal horn


(steering column)

Acoustic warning signal

41

Multifunction lever Turn signal


(steering column)

Turn signal "to the left" on/off

42

Multifunction lever Turn signal


(steering column)

Turn signal "to the right" on/off

43

Multifunction lever Lighting


(steering column) (optional equipment)

High beam on/off

44

Key

Hazard warning system on/off

Hazard warning
system

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 28

MACHINE STRUCTURE

WX210 - WX240

Fig. 8

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 29

Page 8 of 8
No.

Designation

Function

Buzzer

Intermittent warning tone signal, when:

Symbol

- brake pressure too low


- engine oil pressure insufficient
- coolant temperature too high
- admissible load moment exceeded (with
verload warning option)
- no voltage supplied by alternator
- temperature of hydraulic oil too high
- "Stabilizers / levelling blade" raising and
lowering function is on
- severe faults have occurred in electronic
control module
- emergency operation has been activated
Single warning tone signal, when:
- the self-test of the electronic control
module is in progress after "Ignition on"
- the return-flow filters of the hydraulic
system are contaminated
- the machine has been switched over
from stick function to levelling blade /
stabilizers
- for the purpose of follow-up maneuvers
during hammer operations, the machine
is temporarily switched back to adjusting
cylinder by means of the pedal
- faults in the electronic control unit have
occurred that do not constitute a severe
threat to the safety of the operator and
of the machine
Further short acoustic warning signals:
- triple tone in the event of operating errors
- double tone on switching over to forward
travel
- single tone on switching over to reverse
travel
- prolonged single tone when travel direction is shifted to neutral

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 30

MACHINE STRUCTURE

WX210 - WX240

Control elements

10000359.00-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 31

Page 1 of 2
No.

Designation

Function

60

Steering coulmn
and steering wheel

Transfer of steering movement to steered axle

61

Pedal

Travelling

Control of machine travel

62

Pedal

Service brake

Braking travelling movements.

63

Pushbutton

Grab rotation /
Adjustable boom
upper section (optional)

Selects sense of grab rotation: right


(with option "Upper boom section shift operation": slew
to the right

64

Pushbutton

Signalhorn

Acoustic warning signal

65

Pushbutton

Travel direction

Selects forward travel


(No. 101 lit up)

66

Pushbutton

Travel direction

Selects reverse travel


(No. 107 lit up)

67

Pushbutton

Travel direction

Selects neutral travel

68

Locking bolt

OberwagenVerriegelung

Locks up the superstructure and the undercarriage

69

Control lever

Boom

forward - lowering the boom


backward - raising the boom

Bucket

to the right - emptying the bucket


to the left - fillng the bucket

Grab

With grab option:


to the right - opening the grab
to the left - closing the grab

Slewing

to the right superstructure slewing to the right


to the leftsuperstructure slewing to the left

Stick

forward stretching out stick lowering the levelling blade / the stabilizers
backwards retracting the stick raising the levelling blade / the stabilizers.
(see also Nos. 22 - 25)

70

Steuerhebel

Levelling blade /
stabilizers

71

Pushbutton

Levelling

Supplementary activation of the "levelling" mode


(see: "Switching over to "levelling")

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 32

MACHINE STRUCTURE

WX210 - WX240

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 33

Page 2 of 2
No.

Designation

Function

72

Safety lever

Electro-hydraulic
pilot control

Pull up Electro-hydraulic pilot control OFF


Push down Electro-hydraulic pilot control ON
(see: "Switching on the pilot control")

73

Pushbutton

Power-Boost

Brief working with increased engine speed and higher


pressure.
(see: "Power-Boost, function")

74

Pushbutton

75

Pushbutton

Hydraulic hammer
(optional equipment)

Activation of hydraulic hammer

76

Pushbutton

Grab rotation /
Adjustable upper
boom section (optional equipment)

Selects sense of grab rotation: to the left


(with option "Upper boom section shift operation": slew
to the left

77

Pedal
(for equipment
options)

Switches over between "Stick" and "Stabilizers / levelling blade". The buzzer sounds when the "Stabilizers /
levelling blade" function is activated.

Examples:
- with upper boom section shifting equipment
in / out of shifting cylinder
- with hydraulic hammers:
hammer operation
- with hydraulic rotary cutters
rotary cutter operation
- with hydraulic shears
hydraulic shears operation

78

Foot-rest

79

Lever

Steering column
lock

Locks up the steering column in the desired inclination:


push down - steering column can be adjusted.
release lever - steering column locked

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 34

MACHINE STRUCTURE

WX210 - WX240

Multifunction display

10000366.00-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 35

Page 1 of 5
No.

Designation

Function

101

Pilot lamp

Travel direction
indicator

Lights up when forward travel is


active
(see No. 65 in "Control elements")

102

Pilot lamp

Travel direction
indicator

Lights up when turn signal left


(No. 41 in "Switches/Keys") is
activated

103

Pilot lamp

Preheating

Lit up during the preheating cycle


(preheating timer active)

104

Pilot lamp

Main beam

Lit up blue when the headlamps


are on main beam (No. 43 in
"Switches/Keys" is on)

105

Pilot lamp

Superstructure
holding brake

Lit up when the superstructure


holding brake (No. 17) is activated

106

Pilot lamp

Travel direction
indicator

Lights up when turn signal right


(No. 42 in "Switches/Keys") is
activated

107

Pilot lamp

Travel direction
indicator

Lights up when reverse travel is


active
(see No. 66 in "Control elements")

108a Multifunction dis- Time/ operating


play
hours / fuel reserve

Time of day in hours and minutes


/ display of machine operating
hours / fuel reserve.
Fuel level above horizontal line =
OK
Fuel level below horizontal line =
fill up fuel tank

108b Multifunction dis- Time / engine


play
power level

Time of day in hours and minutes


/ graphic display of respective
engine power level.

108c Multifunction dis- Coolant templay


perature / hydraulic oil temperature

Displays the coolant temperature


and the hydraulic oil temperature

Symbol

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 36

MACHINE STRUCTURE

WX210 - WX240

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 37

Page 2 of 5
No.

Designation

108d Multifunction dis- Code


play

Function

Symbol

Input of secret code number for


electronic immobilizer.
(See: "Immobilizer, entering the
code")

108e Multifunction dis- Operating hours Display of operating hours as:


play
- total of operating hours
- partial count
- day count

108f Multifunction dis- Machine


play

Setting:
- of hydraulic oil pressure and of
volumetric flow for up to 4 different hydraulic hammers
- of hydraulic oil pressure and of
volumetric flow for up to 4 different rotary cutters and other
attachments (not applicable to
hydraulic shears).
- slewing power limiting
- degree of damping for equipment movements and travel
function
- activation of the "Auto PowerBoost" function
See working settings of the machine)

108g Multifunction dis- Display


play

Setting of display contrast and


brightness, clock, language and
measuring units.
(See: "Display, settings")

108h Multifunction dis- Information


play

Displays operating data of the


machine and the control system
(central unit (CU), power control
system (PCS), electro-hydraulic
control system (ESX), display
(C4) and keypad modules
(C51,C52,C53).
(See operating data)

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 38

MACHINE STRUCTURE

WX210 - WX240

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 39

Page 3 of 5
No.

Designation

108i Multifunction display

Function
Tester

Symbol

Monitoring and display of process data and settings / operating


status.
This menu is reserved for our
Service Dept. and not accessible
in normal machine operation.

108j Multifunction display

Service

- Display of operating hours (in


detail)
- Display and setting of servicing
intervals

Display

- Calibration of proportional
valves and control valves (control levers), pumps and speedometer
- Fault treatment
- fault recording
- fault details
- fault reset (erasing)
This menu is reserved for our
Service Dept. and not accessible
in normal machine operation.
108 Multifunction disk play

10 Key
9

Fault memory

Fault memory
- Faults occurred are stored in
detail for the individual electronic control units

SET key

Key for selection and confirmation of items in function and navigation menus

110 Key

Arrow key

Key for selection and scroll-down


in function and navigation menus

111 Key

Arrow key

Key for selection and scroll-up or


escape key in function and navigation menus

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 40

MACHINE STRUCTURE

WX210 - WX240

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 41

Page 4 of 5
No.
112

Designation
Warning lamp

Function
Fault message

Symbol

Lights up yellow in the event of


faults which are not safety- or
function-relevant.
When a yellow fault occurs, a
fault number is displayed and a
buzzer warning is sounded in
addition to the yellow warning
lamp lighting up.
If several yellow faults have occurred, they are displayed one
after another at certain intervals.
Instantaneous calling is possible
by depressing the SET key.
The cause of the fault should be
rectified as soon as possible. In
most cases, the machine can
continue to be used with all its
functions.
(See: "Fault codes")

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 42

MACHINE STRUCTURE

WX210 - WX240

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

2 - 43

Page 5 of 5
No.

Designation

113 Warning lamp

Function
Fault message

Symbol

Lights up red, when the safety of


persons (e.g. safety lever defective, overload warning) and the
functioning of main assemblies of
the machine is endangered.
This is the case, for instance,
when there is no engine oil pressure or when the admissible load
moment is being exceeded (with
overload warning option) and
when pressure-relief valves
open.
When a red fault occurs, a fault
number is displayed and an intermittent buzzer warning is
sounded in addition to the red
warning lamp lighting up.
In some fault cases, certain machine functions are deactivated
or can be switched over to emergency operation.
There is also the possibilty of
several faults being indicated at
the same time. If 2 red faults
occur, both are indicated. If a
yellow and red fault occur at the
same time, only the red fault will
be indicated. After removal of the
cause of the red fault, the yellow
fault is indicated.
(See: "Fault codes")

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 44

MACHINE STRUCTURE

WX210 - WX240

Superstructure components, overview

40000486-en

4100772

Fig. 1

Legend
1

Superstructure frame

Hydraulic tank

Counterweight

Control block

Diesel engine

Combined radiator

Fuel tank

Ball-mounted slewing ring

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

Engine assembly components, overview

2 - 45

40000487-en

2987439.000

Fig. 2

Legend
1

Diesel engine

Air filter

Combined radiator

Exhaust system

Coolant expansion tank

Engine bearing

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 46

MACHINE STRUCTURE

WX210 - WX240

Hydraulic system components, overview

40000488-en

4
Fig. 3

Legend
1

Hydraulic tank

Operating elements

Control block

Slewing gearbox

Servo control unit

Hydraulic rotor

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

MACHINE STRUCTURE

Drive unit components, overview

2 - 47

40000489-en

2987437.000

Fig. 4

Legend
1

Diesel engine

Gear pump

Resilient coupling

Speed adjustment motor

Main pumps A 8 V

Intake air temperature sensor

Suction line

Speed sensor

Slewing pump A 4 V

10

Start and grid heater relay

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

2 - 48

MACHINE STRUCTURE

WX210 - WX240

Undercarriage components, overview

40000490-en

Fig. 5

Transmission drive / rigid axis

Steering and swing axis

Fig. 7

Fig. 6

Legend
1

Undercarriage frame

Support

Floating axle support

Rotor, hydraulic and electrical

Ball-mounted slewing ring

Control block

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

Service manual
Section 3 Electrical System
WX210 - WX240

9-91270

3-2

ELECTRICAL SYSTEM

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3-3

3-4

ELECTRICAL SYSTEM

WX210 - WX240

Table of contents

ELECTRICAL SYSTEM.................................................................................. 6
Control ............................................................................................................................................. 6
Introduction .................................................................................................................................................... 6

The electrical system...................................................................................................................... 7


Fundamental notions...................................................................................................................................... 7
Automotive electrical systems........................................................................................................................ 7
Cable harnesses ............................................................................................................................................ 7

Fuses................................................................................................................................................ 8
Checking / replacing the fuses....................................................................................................................... 8
Table of fuses............................................................................................................................................... 10

Electrical circuit diagrams, part number 8916249, 1-42 .......................... 12


Table of contents, page 1 ............................................................................................................................ 13
Table of contents, page 2 ............................................................................................................................ 14
Power supply, starter/engine ....................................................................................................................... 15
Grid Heater / Filter Heater............................................................................................................................ 16
Sensor power supply ................................................................................................................................... 17
Tank sensor / refuelling system ................................................................................................................... 18
Pilot control shutoff....................................................................................................................................... 19
PCS.............................................................................................................................................................. 20
Switches....................................................................................................................................................... 21
Speed adjusting motor ................................................................................................................................. 22
Power supply -CU- ....................................................................................................................................... 23
Driver's cab, voltage converter..................................................................................................................... 24
Driver's cab, wiper and washer .................................................................................................................... 25
Driver's cab .................................................................................................................................................. 26
Driver's cab .................................................................................................................................................. 27
Driver's cab .................................................................................................................................................. 28
Driver's cab .................................................................................................................................................. 29
Steering column lever switch ....................................................................................................................... 30
Inching Function........................................................................................................................................... 31
Lighting......................................................................................................................................................... 32
Lighting......................................................................................................................................................... 33
Lighting......................................................................................................................................................... 34
Speedometer creep speed........................................................................................................................ 35
Valves - air filter control ............................................................................................................................... 36
Service and parking brakes ......................................................................................................................... 37
1st + 2nd Gear - Floating axle ........................................................................................................................ 38
Blower and air conditioner ........................................................................................................................... 39
Auxiliary heating (option) ............................................................................................................................. 40
Hammer / shears frequency (option) ........................................................................................................... 41
Stabilizers / levelling blade (option) ............................................................................................................. 42

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3-5

ESX: power supply....................................................................................................................................... 43


ESX: CAN1, CAN2, diagnosis ..................................................................................................................... 44
ESX: coding ................................................................................................................................................. 45
ESX: valve control........................................................................................................................................ 46
ESX - PCS: valve control ............................................................................................................................. 47
ESX: valve stacking ..................................................................................................................................... 48
ESX: valve control........................................................................................................................................ 49
ESX: slewing initiator ................................................................................................................................... 50
ESX: pressure sensors ................................................................................................................................ 51
CAN-BUS power supply, overview .............................................................................................................. 52
Fuses, overview ........................................................................................................................................... 53
Ground points on the machine, overview .................................................................................................... 54

Electrical circuit diagrams for supplementary functions.......................................................... 55


Hammer equipment...................................................................................................................................... 56
Shears equipment ........................................................................................................................................ 57
Cutter equipment.......................................................................................................................................... 58
Hammer / shears equipment........................................................................................................................ 59
Hammer / cutter equipment ......................................................................................................................... 60
Shears / cutter equipment............................................................................................................................ 61
Hammer / shears / cutter equipment............................................................................................................ 62

Layout of electrical components................................................................................................. 63


Electrical system - central electronics (behind driver's seat) .................................................. 64
Electrical system for electro-hydraulic pilot control ................................................................. 65
Electrical system of pilot-control unit, solenoid valves, sensors and switches..................... 66
Electrical system in engine compartment .................................................................................. 67
Electrical system for undercarriage control block .................................................................... 68
Electrical system for undercarriage stabilization, the fig. shows individual
stabilization variant A4................................................................................................................. 68
Electrical components by code numbers................................................................................... 69
Connector pin assignment table for connector X33A ............................................................... 77
Connector pin assignment table for connector X33B ............................................................... 78
Connector pin assignment table for connector X33C ............................................................... 79
Connector pin assignment table for connector X33D ............................................................... 80
Connector pin assignment table for connector X33E ............................................................... 81
Connector pin assignment table for connector X33P ............................................................... 81

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3-6

ELECTRICAL SYSTEM

WX210 - WX240

ELECTRICAL SYSTEM

40000307-en

Control
Introduction
The description of the machine control is divided
into 3 parts:
- Automotive electrical system
- Electronic systems with
the central electronic unit,
the electro-hydraulic pilot control and
the electronic load-limit regulation.
- Hydraulic system described according to the
power flow in the machine and the individual
functions and combined functions.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

The electrical system

40000317-en

Fundamental notions
See Technical Handbook "Fundamentals of electrical engineering" in the Annex.
Part number:

2440049.00

Automotive electrical systems


See Technical Handbook "Automotive electrical
systems in construction machinery" in the Annex.
Part number:

3-7

2440047.01

Cable harnesses
Cable harnesses are described in the spare-parts
lists from assembly no.
32,000 onwards.
A code number found in the electrical circuit diagram can be looked up in the table "Electrical components by code numbers" with reference to the
corresponding spare-parts sheet for ordering purposes.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3-8

ELECTRICAL SYSTEM

WX210 - WX240

Fuses

10000336-en

Checking / replacing the fuses

Shut off the engine and turn keyswitch to 0 before removing a fuse.
Replace defective fuses only by
fuses of the same rating.

The fuses are housed in a fuse-box in the righthand cover panel (Fig. 1).
Remove the transparent cover of the fuse-box
by unsnapping the clips on both sides. The
fuses are now accessible (Fig. 2). Fuse assignment and rating see: "Table of fuses".
Fig. 1

If an electrical circuit fails, check first the corresponding fuse:


Withdraw the fuse from the holder. For this purpose, the fuse-box contains a special fuse removal tool. (Fig. 2).
Check the fuse. In most cases, a blown fuse
wire can be seen with the naked eye (Fig. 3). In
case of doubt, check the fuse with an ohmmeter
or replace right away by a new one.
If the fuse is defective, insert a new one of the
same rating into the fuse holder.
If the fuse is not defective, check the electrical
components, the connectors and the cables (or
have them checked).

Fig. 2

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3-9

Fig. 4

Location of fuses and modules in the cab and in the engine compartment, legend of Fig. 4:
1

Fuel tank

Grid-Heater fuse

Hydraulic oil reservoir

Batteries

Hydraulic pumps

10

Fuse-box 2, driver's cab

Engine

11

Fuse-box 1, driver's cab

Counterweight

12

Driver's seat

Combined radiator

13

Driver's cab

Starter

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 10

ELECTRICAL SYSTEM

WX210 - WX240

Table of fuses

10000071-en

Pedestal (Fuse box on the right behind the driver's seat, Fig. 1)
FA.1

5A

Power relay (main switch function), central electronics,


Restraining coil engine stop magnet

FA.2

5A

Start relay, option: Grid-Heater-Controller

FA.3

FA.4

2A

ESX ground for sensors

FA.5

15 A

Option: refuelling system

FA.6

5A

Safety switch electro-hydraulic pilot control,


Relay for power supply of central unit,
Pilot control working system pressure switch, pilot control travelling pressure switch

FA.7

5A

Power supply PCS 1)-Box,

FA.8

5A

Parking brake switch, brake pressure switch (stop-light),


Alternator (exciter voltage)

FA.9

10 A

Option: driver's seat compressor, auxiliary heating timer

FA.10

5A

Option: stabilizers / levelling blade

FA.11

10 A

Main beam via relay

FA.12

1A

Power supply for joystick left and right

FA.13

2A

Power supply (ESX) 2)

FA.14

30 A

Power supply (ESX)

FA.15

1A

Power supply for travel pedal and keyboard module on steering wheel

FA.16

5A

Option: Power supply for greasing pump

FA.17

15 A

Option: auxiliary heating

FA.18

5A

Option: auxiliary heating

FA.19

7.5 A

FA.20

FA.21

5A

Option: heating filter relay, Grid-Heater-Controller

FA.22

30 A

Option: heating filter

FA.23

25 A

Stop magnet energizing coil

FA.24

5A

Diagnosis socket CAN1 and CAN2 3)

FA.25

10 A

24V/12V voltage converter supply


Radio and socket, Option: conditioner actuator (electrically operated flap for switching between recirculated and fresh air)

FA.26

2A

Relay for cab interior lighting

FA.27

2A

Power relay (main switch function)

FA.28

15 A

to ignition/starter switch

FA.29

5A

Hazard warning signal switch

- not used -

Option: blower stage 1 for auxiliary heating


- not used -

1)

PCS: Power Contol System

2)

ESX : Electro-hydraulic Controller

3)

CAN: Acronym for Control Area Network (2-wire bus)


Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 11

Pedestal (Fuse box on the right behind the driver's seat, Fig. 1)
FA.30

15 A

FA.31

- not used -

FA.32

- not used -

Blower / air conditioner compressor

Driver's cab (fuse-box on the right beside the driver's seat, Fig. 2)
FB.1

10 A

Option: rotary beacon

FB.2

10 A

Option: floodlamp at the rear of driver's cab

FB.3

10 A

Floodlamp in front of driver's cab

FB.4

10 A

Wiper motor and wash pump

FB.5

5A

Cab interior lighting

FB.6

7.5 A

24V/12V voltage converter supply for radio and socket

FB.7

2A

Power supply for display and keyboard modules in cab

FB.8

5A

Option: frequency switching solenoid

FB.9

5A

Illumination of switches

FB.10

- not used -

FB.11

- not used -

FB.12

- not used -

FB.13

- not used -

FB.14

- not used -

FB.15

- not used -

FB.16

- not used -

Engine compartment
F 20

Fig. 1

125 A

Grid-Heater

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 12

ELECTRICAL SYSTEM

WX210 - WX240

Electrical circuit diagrams, part number 8916249, 1-42


- Table of contents
- Power supply, starter/engine
- Grid Heater / Filter Heater
- Sensor power supply
- Tank sensor / refuelling system
- Pilot control shutoff
- PCS
- Switches
- Speed adjusting motor
- Power supply -CU- Driver's cab, voltage converter
- Driver's cab, wiper and washer
- Driver's cab
- Steering column lever switch
- Inching Function
- Lighting
- Speedometer - creep speed
- Valves - air filter control
- Service and parking brakes
- 1st + 2nd Gear - Floating axle
- Blower and air conditioner
- Auxiliary heating (option)
- Hammer / shears frequency (option)
- Stabilizers / levelling blade (option)
- ESX: power supply
- ESX: CAN1, CAN2, diagnosis
- ESX: coding
- ESX: valve control
- ESX - PCS: valve control
- ESX: valve stacking
- ESX: slewing initiator
- ESX: pressure sensors
- CAN-BUS power supply, overview
- Fuses, overview
- Ground points on the machine, overview

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000491-en

WX210 - WX240

ELECTRICAL SYSTEM

Table of contents, page 1

3 - 13

S0000492-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 14

ELECTRICAL SYSTEM

WX210 - WX240

Table of contents, page 2

S0000493-en

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Power supply, starter/engine

3 - 15

S0000494-de

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 16

ELECTRICAL SYSTEM

WX210 - WX240

Grid Heater / Filter Heater

S0000495-en

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Sensor power supply

3 - 17

S0000496-en

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 18

ELECTRICAL SYSTEM

WX210 - WX240

Tank sensor / refuelling system

S0000497-en

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Pilot control shutoff

3 - 19

S0000498-en

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 20

ELECTRICAL SYSTEM

WX210 - WX240

PCS

40000499-en

Fig. 8

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Switches

3 - 21

S0000500-en

Fig. 9

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 22

ELECTRICAL SYSTEM

WX210 - WX240

Speed adjusting motor

S0000501-en

Fig. 10

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Power supply -CU-

3 - 23

S0000502-en

Fig. 11

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 24

ELECTRICAL SYSTEM

WX210 - WX240

Driver's cab, voltage converter

S0000503-en

Fig. 12

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Driver's cab, wiper and washer

3 - 25

S0000504-en

Fig. 13

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 26

ELECTRICAL SYSTEM

WX210 - WX240

Driver's cab

S0000505-en

Fig. 14

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Driver's cab

3 - 27

S0000506-en

Fig. 15

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 28

ELECTRICAL SYSTEM

WX210 - WX240

Driver's cab

S0000507-en

Fig. 16

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Driver's cab

3 - 29

S0000508-en

Fig. 17

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 30

ELECTRICAL SYSTEM

WX210 - WX240

Steering column lever switch

S0000509-en

Fig. 18

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 31

Inching Function

Fig. 19

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 32

ELECTRICAL SYSTEM

WX210 - WX240

Lighting

S0000510-en

Fig. 20

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Lighting

3 - 33

S0000511-en

Fig. 21

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 34

ELECTRICAL SYSTEM

WX210 - WX240

Lighting

Fig. 22

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Speedometer creep speed

3 - 35

S0000512-en

Fig. 23

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 36

ELECTRICAL SYSTEM

WX210 - WX240

Valves - air filter control

S0000513-en

Fig. 24

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 37

Service and parking brakes

Fig. 25

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 38

ELECTRICAL SYSTEM

WX210 - WX240

1st + 2nd Gear - Floating axle

S0000514-en

Fig. 26

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Blower and air conditioner

3 - 39

S0000515-en

Fig. 27

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 40

ELECTRICAL SYSTEM

WX210 - WX240

Auxiliary heating (option)

S0000516-en

Fig. 28

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Hammer / shears frequency (option)

3 - 41

S0000517-en

Fig. 29

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 42

ELECTRICAL SYSTEM

WX210 - WX240

Stabilizers / levelling blade (option)

S0000518-en

Fig. 30

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

ESX: power supply

3 - 43

S0000519-en

Fig. 31

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 44

ELECTRICAL SYSTEM

WX210 - WX240

ESX: CAN1, CAN2, diagnosis

S0000520-en

Fig. 32

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

ESX: coding

3 - 45

S0000521-en

Fig. 33

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 46

ELECTRICAL SYSTEM

WX210 - WX240

ESX: valve control

S0000522-en

Fig. 34

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

ESX - PCS: valve control

3 - 47

S0000523-en

Fig. 35

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 48

ELECTRICAL SYSTEM

WX210 - WX240

ESX: valve stacking

S0000524-en

Fig. 36

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

ESX: valve control

3 - 49

S0000525-en

Fig. 37

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 50

ELECTRICAL SYSTEM

WX210 - WX240

ESX: slewing initiator

S0000526-en

Fig. 38

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

ESX: pressure sensors

3 - 51

S0000527-en

Fig. 39

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 52

ELECTRICAL SYSTEM

WX210 - WX240

CAN-BUS power supply, overview

S0000528-en

Fig. 40

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Fuses, overview

3 - 53

S0000529-en

Fig. 41

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 54

ELECTRICAL SYSTEM

WX210 - WX240

Ground points on the machine, overview

S0000593-en

Fig. 42

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Electrical circuit diagrams for supplementary functions


- Hammer equipment
- Shears equipment
- Cutter equipment
- Hammer / shears equipment
- Hammer / cutter equipment
- Hears / cutter equipment
- Hammer / shears / cutter equipment

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 55

40000444-en

3 - 56

ELECTRICAL SYSTEM

WX210 - WX240

Hammer equipment

S0000445-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Shears equipment

3 - 57

S0000446-en

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 58

ELECTRICAL SYSTEM

WX210 - WX240

Cutter equipment

S0000447-en

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Hammer / shears equipment

3 - 59

S0000448-en

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 60

ELECTRICAL SYSTEM

WX210 - WX240

Hammer / cutter equipment

S0000449-en

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Shears / cutter equipment

3 - 61

S0000450-en

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 62

ELECTRICAL SYSTEM

WX210 - WX240

Hammer / shears / cutter equipment

S0000451-en

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Layout of electrical components

3 - 63

S0000530-en

Electrical system and central electronics (behind the driver's seat) and layout of electrical components such
as fuses, diagnosis sockets, relays, diodes, connectors and terminals

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 64

ELECTRICAL SYSTEM

WX210 - WX240

Electrical system - central electronics (behind driver's seat)


Layout of central electronic unit A100 and PCS load-limit regulator A10

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 65

Electrical system for electro-hydraulic pilot control


ESX controller, proportional valves and pressure sensors on control block, proportional valves and slewing
angle sensor on slewing pump

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 66

ELECTRICAL SYSTEM

WX210 - WX240

Electrical system of pilot-control unit, solenoid valves, sensors and switches

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

Electrical system in engine compartment

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 67

3 - 68

ELECTRICAL SYSTEM

WX210 - WX240

Electrical system for undercarriage control block

Fig. 6

Electrical system for undercarriage stabilization, the fig. shows individual


stabilization variant A4

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 69

Electrical components by code numbers


BMK

Deutsch

Englisch

40000318-en
Bgr

a10

GRENZLASTREGLER

LOAD LIMIT GOVERNOR

32

a100

ZENTRALELEKTRONIK BEDIENPULT

CENTRAL ELECTRONIC UNIT

32

PLUG/SOCKET CENTRAL ELECTRONIC

32

PLUG/SOCKET CENTRAL ELECTRONIC

32

PLUG/SOCKET CENTRAL ELECTRONIC

32

PLUG/SOCKET CENTRAL ELECTRONIC

32

PLUG/SOCKET CENTRAL ELECTRONIC

32

PLUG/SOCKET LOAD LIMIT GOVERNOR 15 POLE


HOUSING_EARTH LOAD LIMIT GOVERNOR
DIAGNOSTIC UNIT CONNECTOR

32

A100X1

STECKVERBINDUNG ZENTRALELEKTRONIK
A100X2A STECKVERBINDUNG ZENTRALELEKTRONIK
A100X3A STECKVERBINDUNG ZENTRALELEKTRONIK
a100x6
STECKVERBINDUNG ZENTRALELEKTRONIK
A100X7 STECKVERBINDUNG ZENTRALELEKTRONIK
A10X1
STECKVERBINDUNG GRENZLASTREGLER 15 POLIG
A10X31 GEHAEUSE-MASSE GRENZLASTREGLER
A10X4

DIAGNOSESTECKDOSE PMS

32
32

Ugr

Bezeichnung

150 ZENTRALELEKTRONIK
EINBAU
150 ZENTRALELEKTRONIK
EINBAU
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK

Bezeichnung EN
CENTRAL ELECTRONIC INSTALL.MATERIAL
CENTRAL ELECTRONIC INSTALL.MATERIAL
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC

a17

GRID HEATER CONTROLLER

a400

DISPLAY-MODUL

DISPLAY-MODUL

32

a501

TASTATUR-MODUL 1

KEYBOARD-MODUL 1

32

a502

TASTATUR-MODUL 2

KEYBOARD-MODUL 2

32

a503

TASTATUR-MODUL 3

KEYBOARD-MODUL 3

18

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
100 LENKUNGSSAEULE
STEERING COLUMN

A56

32

470 BETAETIGUNG EINBAU

34

141 KONSOLE ANBAUTEILE

32

470 BETAETIGUNG EINBAU

32

413 KABELBAUM KONSOLE

CONTROL DEVICE INSTALLATION


CABLE HARNESS BRACKET

32

413 KABELBAUM KONSOLE

CABLE HARNESS BRACKET

32

470 BETAETIGUNG EINBAU

CONTROL DEVICE INSTALLATION


CONTROL DEVICE INSTALLATION
BRACKET MOUNTING PARTS

32

413 KABELBAUM KONSOLE

a61

VORSTEUERHEBEL HYDRAULIK RECHTS PILOT CONTROL-LEVER HYDRAULIC


RIGHT
VORSTEUERHEBEL HYDRAULIK RECHTS PILOT CONTROL-LEVER HYDRAULIC
RIGHT
STECKVERBINDUNG VORSTEUERHEBEL PLUG/SOCKET PILOT CONTROLRECHTS
LEVER HYDRAULIC RIGHT
STECKVERBINDUNG VORSTEUERHEBEL PLUG/SOCKET PILOT CONTROLRECHTS
LEVER HYDRAULIC RIGHT
STECKVERBINDUNG VORSTEUERHEBEL PLUG/SOCKET PILOT CONTROLRECHTS
LEVER HYDRAULIC RIGHT
STECKVERBINDUNG VORSTEUERHEBEL PLUG/SOCKET PILOT CONTROLRECHTS
LEVER HYDRAULIC RIGHT
VORSTEUERHEBEL HYDRAULIK LINKS
PILOT CONTROL-LEVER HYDRAULIC
LEFT
VORSTEUERHEBEL HYDRAULIK LINKS
PILOT CONTROL-LEVER HYDRAULIC
LEFT
STECKVERBINDUNG VORSTEUERHEBEL PLUG/SOCKET PILOT CONTROLLINKS
LEVER HYDRAULIC LEFT
STECKVERBINDUNG VORSTEUERHEBEL PLUG/SOCKET PILOT CONTROLLINKS
LEVER HYDRAULIC LEFT
FAHRPEDAL / MASTER
ACCELERATOR PEDAL / MASTER

32

470 BETAETIGUNG EINBAU

a61.1

PEDAL / SLAVE1

32

A61X1

STECKVERBINDER FAHRPEDAL/MASTER PLUG/SOCKET ACCELERATOR PEDAL /


MASTER
STECKVERBINDER FAHRPEDAL/MASTER PLUG/SOCKET ACCELERATOR PEDAL /
MASTER
SCHALTKASTEN BETANKUNGSANLAGE

A56X1

a56x2

a57

A57X1

A61X2
A67
A7.3

PEDAL / SLAVE1

a90.2

HAUPT-STEUERGERAET ELEKTROHYDRAULIK
STECKVERBINDUNG HAUPTSTEUERGERAET
RADIO

RADIO

a90.3

LAUTSPRECHER

B10
b10.1

A7.3X4

470 BETAETIGUNG EINBAU

34

141 KONSOLE ANBAUTEILE

32

470 BETAETIGUNG EINBAU

32
32

CONTROL DEVICE INSTALLATION


CABLE HARNESS BRACKET

CONTROL DEVICE INSTALLATION


470 BETAETIGUNG EINBAU
CONTROL DEVICE INSTALLATION
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

32

153 KABELBAUM ZENTRALELEKTRONIK

LOUDSPEAKER

32

DRUCKGEBER FAHREN

PRESSURE SENSOR - TRAVEL

32

DREHZAHLSENSOR

SPEED SENSOR

13

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
011 MOTOR ANBAUTEILE
MOTOR MOUNTING PARTS

DREHZAHLSENSOR

SPEED SENSOR

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

THERMOSTAT VORWRMUNG

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

b13.1

THERMOSTAT VORWRMUNG KRAFTSTOFF


THERMOSTAT VORWRMUNG KRAFTSTOFF
KUEHLWASSERTEMP.-GEBER

246 KRAFTSTOFFFILTER
ANBAUTEILE
475 THERMOSTAT

FUEL FILTER MOUNTING


PARTS
THERMOSTAT

b2

B116

PLUG/SOCKET MAIN CONTROLLER

32

CONTROL DEVICE INSTALLATION


BRACKET MOUNTING PARTS

CABLE HARNESS CENTRAL


ELECTRONIC

THERMOSTAT VORWRMUNG

95
95
32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

TANKSENSOR

COOLING-WATER TEMPERATURE
SENSOR
COOLING-WATER TEMPERATURE
SENSOR
TANK SENSOR

10

202 KRAFTSTOFFTANK

FUEL TANK

B210

DRUCKGEBER HAUPTPUMPE 2

PRESSURE SENSOR - MAINPUMP 2

32

B211

DRUCKGEBER HAUPTPUMPE 1

PRESSURE SENSOR - MAINPUMP 1

32

B212

DRUCKGEBER SCHWENKPUMPE

PRESSURE SENSOR - SWING PUMP

32

b213

WINKELGEBER SCHWENKPUMPE
WINKELGEBER SCHWENKPUMPE

ANGEL TRANSMITTER - SWING PUMP


ANGEL TRANSMITTER - SWING PUMP

22
32

B239

DRUCKSENSOR

SENSOR LOAD

32

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
030 SCHWENKPUMPE
SWING PUMP
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

KUEHLWASSERTEMP.-GEBER

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 70

ELECTRICAL SYSTEM

BMK

Deutsch

Englisch

b35.2

DREHZAHLSENSOR SCHWENKEN

B7

e1

DREHZAHLGEBER GETRIEBESCHALTUNG
DREHZAHLGEBER GETRIEBESCHALTUNG
DRUCKGEBER AUSLEGER KOLBENFLAECHE
SCHEINWERFER LINKS

REV. TRANSMITTER ACUTUATING


ELEMENT
REV. TRANSMITTER ACUTUATING
ELEMENT
PRESSURE SENSOR - BOOM PISTON
SIDE
LH HEADLIGHT

e12.1

KENNZEICHENLEUCHTE LINKS

NUMBER PLATE LIGHT, LEFT

e12.2

KENNZEICHENLEUCHTE RECHTS

NUMBER PLATE LIGHT, RIGHT

e1e1

GLUEHLAMPE FAHRLICHT

e1e2

GLUEHLAMPE STANDLICHT

B74

Bezeichnung

201 BELEUCHTUNG FRONT


ANBAUTEILE

BULB, HEADLIGHT

32

LAMP - PARKING LIGHT

32
32

201 BELEUCHTUNG FRONT


ANBAUTEILE
201 BELEUCHTUNG FRONT
ANBAUTEILE
201 BELEUCHTUNG FRONT
ANBAUTEILE

ILLUMINATION FRONT MOUNTING PARTS


ILLUMINATION FRONT MOUNTING PARTS
ILLUMINATION FRONT MOUNTING PARTS

SCHEINWERFER RECHTS

RH HEADLIGHT

BLINKLEUCHTE VORNE LINKS

TURN SIGNAL FRONT LEFT

e23.1

BLINKLEUCHTE VORNE RECHTS

TURN SIGNAL FRONT RIGHT

e2e2

GLUEHLAMPE STANDLICHT

LAMP - PARKING LIGHT

e3

WORKING LIGHT, BOOM LEFT

e32

ARBEITSSCHEINWERFER AUSLEGER
LINKS
ARBEITSSCHEINWERFER FAHRERHAUS
LINKS
ARBEITSSCHEINWERFER FAHRERHAUS
HINTEN LINKS
SCHLEIFRINGKOERPER

e36

RUNDUMKENNLEUCHTE

E36.1

32
32

020 HYDRAULIKANLAGE
UNTERWAGEN
123 KABELBAUM UNTERWAGEN
113 KABELBAUM OBERWAGEN

Bezeichnung EN

32

e22.1

20

Ugr

HYDRAULIC SYSTEM LOWER


CARRIAGE
CABLE HARNESS LOWER
CARRIAGE
CABLE HARNESS UPPER
CARRIAGE
ILLUMINATION FRONT MOUNTING PARTS

e2

e3.4

Bgr

WX210 - WX240

WORKING LIGHT CAB L.H.

32

HEADLAMP DRIVER`S CAB,

32

SLIP RING

33

ROTARY BEACON

32

RUNDUMKENNLEUCHTE

ROTARY BEACON

32

RUNDUMKENNLEUCHTE

ROTARY BEACON

32

WORKING LIGHT, BOOM RIGHT

E5

ARBEITSSCHEINWERFER AUSLEGER
RECHTS
ARBEITSSCHEINWERFER FAHRERHAUS
RECHTS
ARBEITSSCHEINWERFER FAHRERHAUS
HINTEN RECHTS
SCHLUSSLEUCHTE LINKS

TAIL LIGHT, LEFT

32

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
212 BELEUCHTUNG HECK
ILLUMINATION REAR

e5e1

GLUEHLAMPE SCHLUSSLICHT

LAMP - TAIL LIGHT

32

212 BELEUCHTUNG HECK

ILLUMINATION REAR

e5e2
e6

GLUEHLAMPE BREMSLICHT
SCHLUSSLEUCHTE RECHTS

LAMP - STOP LIGHT


TAIL LIGHT, RIGHT

32
32

212 BELEUCHTUNG HECK


212 BELEUCHTUNG HECK

ILLUMINATION REAR
ILLUMINATION REAR

e6e1

GLUEHLAMPE SCHLUSSLICHT

LAMP - TAIL LIGHT

32

212 BELEUCHTUNG HECK

ILLUMINATION REAR

e6e2

GLUEHLAMPE BREMSLICHT

LAMP - STOP LIGHT

32

212 BELEUCHTUNG HECK

ILLUMINATION REAR

e7

BLINKLEUCHTE LINKS

BLINKER LEFT

32

860 BLINKLEUCHTE EINBAU

TURN SIGNAL LIGHT INSTALL.MATERIAL

e72

KLIMAANLAGE

AIR CONDITION

e8

BLINKLEUCHTE RECHTS

BLINKER RIGHT

32

860 BLINKLEUCHTE EINBAU

e9

INNENLEUCHTE

INTERIOR LIGHT

32

esx

MAIN CONTROLLER ELECTRICHYDRAULIC


HOUSING EARTH

34

ESXGehM
f20

HAUPT-STEUERGERAET ELEKTROHYDRAULIK
GEHAEUSEMASSE
SICHERUNG: KALTSTARTANLAGE

FUSE: COLD STARTING SYSTEM

FA.1

SICHERUNG

FUSE

32

fa.10

SICHERUNG

FUSE

32

fa.11

SICHERUNG

FUSE

32

fa.12

SICHERUNG

FUSE

32

fa.13

SICHERUNG

FUSE

32

e3.6

e4
e4.4
e4.6

WORKING LIGHT CAB R.H.

32

HEADLIGHT DRIVER` CAB

32

32

fa.14

SICHERUNG

FUSE

32

fa.15

SICHERUNG

FUSE

32

fa.16

SICHERUNG

FUSE

32

fa.17

SICHERUNG

FUSE

32

fa.18

SICHERUNG

FUSE

32

fa.19

SICHERUNG

FUSE

32

fa.2

SICHERUNG

FUSE

32

fa.21

SICHERUNG

FUSE

32

fa.22

SICHERUNG

FUSE

32

fa.23

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
012 SCHLEIFRINGKOERPER
SLIPRING UNIT
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB

TURN SIGNAL LIGHT INSTALL.MATERIAL


510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
101 PODESTPLATTE ANBAUPLATFORM PLATE MOUNTING
TEILE
PARTS
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK

CABLE HARNESS CENTRAL


ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

BMK

ELECTRICAL SYSTEM

Deutsch

Englisch

Bgr

Fa.24

SICHERUNG

FUSE

32

fa.25

SICHERUNG

FUSE

32

fa.26

SICHERUNG

FUSE

32

fa.27

SICHERUNG

FUSE

32

fa.28

SICHERUNG

FUSE

32

fa.29

SICHERUNG

FUSE

32

Ugr

3 - 71

Bezeichnung

Bezeichnung EN

fa.4

SICHERUNG

FUSE

32

fa.5

SICHERUNG

FUSE

32

fa.6

SICHERUNG

FUSE

32

fa.7

SICHERUNG

FUSE

32

fa.8

SICHERUNG

FUSE

32

fa.9

SICHERUNG

FUSE

32

fb.1

SICHERUNG

FUSE

32

153 KABELBAUM ZENTRALELEKTRONIK


153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
510 KABELBAUM FAHRERHAUS

fb.2

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

fb.3

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

fb.4

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

fb.5

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

fb.6

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

fb.7

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

fb.8

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

fb.9

SICHERUNG

FUSE

32

510 KABELBAUM FAHRERHAUS

g1

GENERATOR
GENERATOR

ALTERNATOR
ALTERNATOR

95
32

612 GENERATOR
253 KABELBAUM MOTOR

CABLE HARNESS CENTRAL


ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
CABLE HARNESS OPERATORS
CAB
GENERATOR
CABLE HARNESS MOTOR

g1.1
g1.2

BATTERIE
BATTERIE

BATTERY
BATTERY

31
31

300 BATTERIE EINBAU


300 BATTERIE EINBAU

BATTERY INSTALL.MATERIAL
BATTERY INSTALL.MATERIAL

h7

SIGNALHORN

HORN

31

874 FANFARE EINBAU

HORN INSTALL.MATERIAL

SIGNALHORN

HORN

32

K-ESX

RELAIS ESX

RELAY ESX

32

K1

RELAIS ANLASSPERRE

RELAY - START INHIBIT

32

k1.5

LEISTUNGSRELAIS

POWER RELAY

13

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
011 MOTOR ANBAUTEILE
MOTOR MOUNTING PARTS

LEISTUNGSRELAIS

POWER RELAY

32

LEISTUNGSRELAIS

POWER RELAY

32

110 ELEKTROANLAGE RAHMEN ELECTRICAL SYSTEM FRAME


OBERWAGEN
UPPER CARRIAGE
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR

fa.3

SICHERUNG

FUSE

32

fa.30

SICHERUNG

FUSE

32

k1.7

RELAIS KALTSTARTANLAGE

RELAY COLD STARTING SYSTEM

13

011 MOTOR ANBAUTEILE

RELAIS KALTSTARTANLAGE

RELAY COLD STARTING SYSTEM

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

k10.1

HAUPTLEISTUNGSRELAIS

MAIN POWER RELAY

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

K100

RELAY POWER SUPPLY CENTRAL


UNIT
RELAY FILTER HEATER

32

K20.3

RELAIS SPANNUNGSVERSORGUNG
CENTRAL UNIT
RELAIS FILTER HEATER

K20.4

RELAIS FILTER HEATER

RELAY FILTER HEATER

32

K202.A

FREIGABE ABSTUETZUNG

RELAY-STABILIZER ENABLE

32

153 KABELBAUM ZENTRALELEKTRONIK


153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK
153 KABELBAUM ZENTRALELEKTRONIK

CABLE HARNESS CENTRAL


ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS CENTRAL
ELECTRONIC

32

K202.B

FREIGABE ABSTUETZUNG

RELAY-STABILIZER ENABLE

32

K31

RELAIS STANDHEIZUNG

AUXILIARA HEATING RELAY

32

K33

RELAIS SPANNUNGSWANDLER

RELAY - VOLTAGE CONVERTER

32

K5.1

RELAIS AUFBLENDLICHT

RELAY - TRAVELLING LIGHT

32

MOTOR MOUNTING PARTS

k67

RELAIS BETANKUNGSANLAGE

RELAY FUELLING SYSTEM

K67.1

RELAIS BETANKUNGSANLAGE

RELAY FUELLING SYSTEM

m1

STARTER

STARTER

95

660 ANLASSER

STARTER

STARTER

STARTER

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

DREHZAHLVERSTELLMOTOR

SPEED ADJUSTING ACTUATOR

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

DREHZAHLVERSTELLMOTOR

SPEED ADJUSTING ACTUATOR

13

REGULATION MOTOR SPEED

GEBLAESE

FAN

27

110 VERSTELLUNG MOTOR


DREHZAHL
012 HEIZUNG

M10

m2

HEATING

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 72

ELECTRICAL SYSTEM

BMK
m3

Deutsch
SCHEIBENWISCHERMOTOR

Englisch

Bgr

WINDSCREEN WIPER MOTOR

32
32

Ugr

WX210 - WX240
Bezeichnung

Bezeichnung EN

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB

m4

SCHEIBENWASCHPUMPE

W/S WASHER PUMP

m67

BETANKUNGSPUMPE

FILLING PUMP

R10.3

TEMPERATURFUEHLER LADELUFT

CHARGE AIR TEMP.SENSOR

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

TEMPERATURFUEHLER LADELUFT

CHARGE AIR TEMP.SENSOR

13

011 MOTOR ANBAUTEILE

MOTOR MOUNTING PARTS

32
10

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
102 HYDRAULIKTANK
HYD. OIL TANK

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

95

INLET PIPE MOUNTING PARTS

BRACKET MOUNTING PARTS

R14

R17

TEMPERATURFUEHLER HYDRAULIKOEL TEMPERATURE PROBE - HYDRAULIC


OIL
TEMPERATURFUEHLER HYDRAULIKOEL TEMPERATURE PROBE - HYDRAULIC
OIL
HEIZWIDERSTAND VORWAERMUNG
HEATING RESISTOR PREHEATING
LADELUFT
CHARGE AIR
HEIZWIDERSTAND VORWAERMUNG
HEATING RESISTOR PREHEATING
LADELUFT
CHARGE AIR
KRAFTSTOFFVORWRMUNG
FUEL PREHEATING
KRAFTSTOFFVORWRMUNG

FUEL PREHEATING

32

380 ANSAUGLEITUNG ANBAUTEILE


246 KRAFTSTOFFFILTER
ANBAUTEILE
253 KABELBAUM MOTOR

POTENTIOMETER
MAX.GESCHWINDIGKEIT (INCHING)
FILTER HEATER

INCHING

34

141 KONSOLE ANBAUTEILE

FILTER HEATER

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

FILTER HEATER

FILTER HEATER

95

STARTSCHALTER

START BUTTON

34

246 KRAFTSTOFFFILTER
ANBAUTEILE
141 KONSOLE ANBAUTEILE

FUEL FILTER MOUNTING


PARTS
BRACKET MOUNTING PARTS

STARTSCHALTER

START BUTTON

32

413 KABELBAUM KONSOLE

CABLE HARNESS BRACKET

STARTSCHALTER

START BUTTON

34

141 KONSOLE ANBAUTEILE

BRACKET MOUNTING PARTS

ENDTASTER ABSCHALTUNG VORSTEUERDRUCK


ENDTASTER ABSCHALTUNG VORSTEUERDRUCK
DRUCKSCHALTER UEBERWACHUNG
VORSTEUERDRUCK
DRUCKSCHALTER UEBERWACHUNG
VORSTEUERDRUCK
OELDRUCKSCHALTER

LIMIT SWITCH PILOT PRESSURE CUTOFF


LIMIT SWITCH PILOT PRESSURE CUTOFF
PRESSURE SWITCH - PILOT PRESSURE MONITOR
PRESSURE SWITCH - PILOT PRESSURE MONITOR
OIL PRESSURE SWITCH

32

413 KABELBAUM KONSOLE

CABLE HARNESS BRACKET

34

141 KONSOLE ANBAUTEILE

BRACKET MOUNTING PARTS

23

240 VENTILVERKETTUNG
VALVE INTERCONN. INEINBAU
STALL.MATERIAL
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR

OELDRUCKSCHALTER

OIL PRESSURE SWITCH

95

414 OELMESSTAB ANBAUTEILE DIPSTICK MOUNTING PARTS

S15

FILTERSCHALTER HYDRAULIK

FILTER SWITCH

32

FILTERSCHALTER HYDRAULIK

FILTER SWITCH

10

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
102 HYDRAULIKTANK
HYD. OIL TANK

s15.1

SCHALTER LUFTFILTERVERSCHMUTZUNG
SCHALTER LUFTFILTERVERSCHMUTZUNG
HANDBREMSSCHALTER

SWITCH - AIR FILTER CONTAMINATED

13

230 ANSAUGANLAGE EINBAU

SWITCH - AIR FILTER CONTAMINATED

32

253 KABELBAUM MOTOR

HANDBRAKE SWITCH

32

413 KABELBAUM KONSOLE

CABLE HARNESS BRACKET

HANDBREMSSCHALTER

HANDBRAKE SWITCH

34

141 KONSOLE ANBAUTEILE

BRACKET MOUNTING PARTS


CONTROL BLOCK

r19

R201
R21

S1

S113

s113.4

S12

S16
s16.1

95

32
32

HANDBREMSSCHALTER

HANDBRAKE SWITCH

23

612 STEUERBLOCK

HANDBREMSSCHALTER

HANDBRAKE SWITCH

32

S17

DRUCKSCHALTER LENKUNG

PRESSURE SWITCH - STEERING

32

S18

BREMSLICHTSCHALTER

BRAKE LIGHT SWITCH

32

S18.1

DRUCKSCHALTER MINDESTBREMSDRUCK
DRUCKSCHALTER BETRIEBSBREMSE

PRESSURE SWITCH - MINIMUM BRAKE


PRESSURE

32

FUEL FILTER MOUNTING


PARTS
CABLE HARNESS MOTOR

INTAKE SYSTEM INSTALL.MATERIAL


CABLE HARNESS MOTOR

S20

WARNBLINKSCHALTER

HAZARD WARNING SWITCH

18

123 KABELBAUM UNTERWACABLE HARNESS LOWER


GEN
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
211 SCHALTVENTIL ANBAUTEI- SHIFT VALVE
LE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
010 LENKUNG EINBAU
STEERING INSTALL.MATERIAL

s23

LENKSTOCKSCHALTER

DIRECTION SWITCH

18

010 LENKUNG EINBAU

s23.6

WISCHER VORN

WISHER-FRONT

32

s290

PRESSURE SWITCH - PILOT PRESSURE MONITOR


PRESSURE SWITCH - PILOT PRESSURE MONITOR
SWITCH - WINDSREEN WIPER

23

s3.3

DRUCKSCHALTER UEBERWACHUNG
VORSTEUERDRUCK
DRUCKSCHALTER UEBERWACHUNG
VORSTEUERDRUCK
SCHALTER SCHEIBENWISCHER VORN

s30.1

SCHALTER MAGNETANLAGE

SWITCH - ELECTRO-MAGNET

32

s35.2

DREHZAHLSENSOR SCHWENKWERKBREMSE
SCHALTER RUNDUMKENNLEUCHTE

SPEED SENSOR - SLEWING-GEAR


BRAKE
SWITCH - GIRATORY BEACON

16

SCHALTER UMSCHALTUNG GREIFER


AOT
SCHALTER HAMMER

SWITCH - CHANGING DEVICE GRAB /


BOOM TOP
SWITCH HAMMER

32

FREQUENCY SWITCH-OVER FOR


HAMMER
SWITCH FOR SHEARS

32

s39.5

SCHALTER FREQUENZUMSCHALTUNG
HAMMER
SCHALTER SCHERE

s39.8

SCHALTER FRAESE

SWITCH MILL

32

S39.9

DRUCKSCHALTER UMSCHALTUNG
HAMMER/SCHERE

PRESSURE SWITCH - CHANGING


DEVICE HAMMER / SHEARS

32

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
240 VENTILVERKETTUNG
VALVE INTERCONN. INEINBAU
STALL.MATERIAL
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
030 SCHWENKGETRIEBE
SLEWING GEAR INEINBAU
STALL.MATERIAL
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

S18.2

23

DRUCKSCHALTER BETRIEBSBREMSE

s36
s37.7
s39
s39.3

32

32
32

32

32

32

STEERING INSTALL.MATERIAL

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240
BMK

ELECTRICAL SYSTEM
Deutsch

Englisch

Bgr

Ugr

3 - 73
Bezeichnung

Bezeichnung EN

s4

SCHALTER SCHEIBENWASCHANLAGE

SWITCH - WINDSREEN WASHER

32

S48.1

SCHALTER ABSTUETZUNG VORNE


LINKS ODER PLANIERSCHILD

SWITCH - STABILIZER FRONT LEFT OR


DOZER BLADE

32

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
413 KABELBAUM KONSOLE
CABLE HARNESS BRACKET

S48.2

SCHALTER ABSTUETZUNG VORNE


RECHTS
SCHALTER ABSTUETZUNG HINTEN
LINKS
SCHALTER ABSTUETZUNG HINTEN
RECHTS
TASTER SCHNELLWECHSLER

SWITCH - STABILIZER FRONT RIGHT

32

413 KABELBAUM KONSOLE

CABLE HARNESS BRACKET

SWITCH - STABILIZER REAR LEFT

32

413 KABELBAUM KONSOLE

CABLE HARNESS BRACKET

SWITCH - STABILIZER REAR RIGHT

32

413 KABELBAUM KONSOLE

CABLE HARNESS BRACKET

BUTTON - QUICK-HITCH

32

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
432 TROCKNER
DRYER

S48.3
S48.4
s50.1
s53.1

s72.1

SCHALTER ARBEITSSCHEINWERFR
VORN
SCHALTER ARBEITSSCHEINWERFER
HINTEN
DRUCKSCHALTER PENDELACHSBLOCKIERUNG
DRUCKSCHALTER KLIMAANLAGE

s74

DRUCKSCHALTER AUSLEGER

PRESSURE SWITCH - BOOM

20

s9

SCHALTER INNENLEUCHTE

SWITCH - INTERIOR LIGHT

32

t33

SPANNUNGSWANDLER 24V/12V

SPANNUNGSVERSORGUNG 24V/12V

32

V1

ENTKOPPELDIODE

UNCOUPLING DIODE

32

V16.2

ENTKOPPELDIODE

UNCOUPLING DIODE

32
32

153 KABELBAUM ZENTRALELEKTRONIK

CABLE HARNESS CENTRAL


ELECTRONIC
CABLE HARNESS BATTERY

s53.2
S62.1

SWITCH - WORKING LIGHT, FRONT

32

SWITCH - WORKING LIGHT, REAR

32

PRESSURE SWITCH - AXLE BLOCK

32

PRESSUR. SWITCH AIR CONDITION

27

310 HYDRAULIKANLAGE
HYDRAULIC SYSTEM HIGH
HOCHDRUCK
PRESSURE
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
413 KABELBAUM KONSOLE
CABLE HARNESS BRACKET

v67
V67.1

ENTKOPPELDIODE

RELEASING DIODE

V67.2

ENTKOPPELDIODE

RELEASING DIODE

w16

VERBINDUNGSKABEL BATTERIEN

CABLE BATTERY

32

173 KABELBAUM BATTERIE

w17

MASSEKABEL PODEST

PLATFORM EARTH CABLE

32

w22

MASSEBAND BATTERIEN

BATTERY EARTH

32

110 ELEKTROANLAGE RAHMEN ELECTRICAL SYSTEM FRAME


OBERWAGEN
UPPER CARRIAGE
173 KABELBAUM BATTERIE
CABLE HARNESS BATTERY

w23

MASSEBAND MOTOR

ENGINE EARTH

32

X10

B+ VERTEILER

B+ DISTRIBUTOR

32

X100B

STECKVERBINDUNG MOTOR

PLUG/SOCKET MOTOR

32

X103

STECKVERBINDUNG

PLUG/SOCKET

32

STECKVERBINDUNG

PLUG/SOCKET

32

x103.1

PLUG/SOCKET DIRECTION SWITCH

32

PLUG/SOCKET DIRECTION SWITCH

32

x110

STECKVERBINDUNG LENKSTOCKSCHALTER
STECKVERBINDUNG LENKSTOCKSCHALTER
STECKVERBINDUNG FAHRERSITZ

PLUG/SOCKET OPERATORS SEAT

32

X12.31

MASSEVERBINDUNG FAHRERHAUS

EARTH CAB

X12A

STECKVERBINDUNG FAHRERHAUS

PLUG/SOCKET CAB

32

STECKVERBINDUNG FAHRERHAUS

PLUG/SOCKET CAB

32

X12B

STECKVERBINDUNG FAHRERHAUS

PLUG/SOCKET CAB

32

STECKVERBINDUNG FAHRERHAUS

PLUG/SOCKET CAB

32

X12CAN

STECKVERBINDUNG FAHRERHAUS

PLUG/SOCKET CAB

32

X201

STECKVERBINDUNG FAHREN

PLUG/SOCKET TRAVEL

32

X30.2

B+ VERTEILER

B+ DISTRIBUTOR

32

X30.CU

B+ VERTEILER

B+ DISTRIBUTOR

32

x305

STECKVERBINDUNG DISPLAY

PLUG/SOCKET DISPLAY

32

x306

STECKVERBINDUNG DISPLAY

PLUG/SOCKET DISPLAY

32

x307

STECKVERBINDUNG DISPLAY

PLUG/SOCKET DISPLAY

32

X31

MASSESTERN

FLAT-PIN PLUG

32

MASSESTERN

FLAT-PIN PLUG

32

MASSESTERN

FLAT-PIN PLUG

32

MASSEVERBINDUNG OBERWAGEN
MASSEVERBINDUNG FAHRERHAUS

EARTH UPPERCARRIAGE
EARTH CAB

32
32

X31.0
X31.FH
X31.P

MASSEVERBINDUNG PODESTPLATTE

EARTH PLATFORM

32

x31.u

MASSEVERBINDUNG UNTERWAGEN

EARTH UNDERCARRIAGE

32

x31.u1

MASSEVERBINDUNG UNTERWAGEN

EARTH UNDERCARRIAGE

32

STECKDOSE 12V

SOCKET 12V

32

110 ELEKTROANLAGE RAHMEN


OBERWAGEN
153 KABELBAUM ZENTRALELEKTRONIK
253 KABELBAUM MOTOR

ELECTRICAL SYSTEM FRAME


UPPER CARRIAGE
CABLE HARNESS CENTRAL
ELECTRONIC
CABLE HARNESS MOTOR

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
463 KABELBAUM LENKSTOCK- CABLE HARNESS SWITCH
SCHALTER
463 KABELBAUM LENKSTOCK- CABLE HARNESS SWITCH
SCHALTER
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
413 KABELBAUM KONSOLE
CABLE HARNESS BRACKET
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
123 KABELBAUM UNTERWACABLE HARNESS LOWER
GEN
CARRIAGE
123 KABELBAUM UNTERWACABLE HARNESS LOWER
GEN
CARRIAGE

x31a
x33.6

510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS


CAB

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 74
BMK

ELECTRICAL SYSTEM
Deutsch

Englisch

Bgr

X33A

STECKVERBINDUNG OBERWAGEN

PLUG/SOCKET UPPERCARRIAGE

32

STECKVERBINDUNG OBERWAGEN

PLUG/SOCKET UPPERCARRIAGE

32

X33B

STECKVERBINDUNG MOTOR

PLUG/SOCKET MOTOR

32

STECKVERBINDUNG MOTOR

PLUG/SOCKET MOTOR

32

X33C

STECKVERBINDUNG MH-FUNKTION

32

X33D

STECKVERBINDUNG ESX

PLUG/SOCKET WHEELED HYDRAULIC FUNTION


PLUG/SOCKET WHEELED HYDRAULIC FUNTION
PLUG/SOCKET ESX

32

STECKVERBINDUNG ESX

PLUG/SOCKET ESX

32

X33E

STECKVERBINDUNG ESX

PLUG/SOCKET ESX

32

STECKVERBINDUNG ESX

PLUG/SOCKET ESX

32

STECKVERBINDUNG EINSPEISUNG
FAHRERHAUS
STECKVERBINDUNG EINSPEISUNG
FAHRERHAUS
STECKVERBINDUNG

PLUG/SOCKET INCOMING SUPPLY

32

PLUG/SOCKET INCOMING SUPPLY

32

PLUG/SOCKET

32

STECKVERBINDUNG MH-FUNKTION

X33P

X3A

32

Ugr

WX210 - WX240
Bezeichnung

Bezeichnung EN

153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL


ELEKTRONIK
ELECTRONIC
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
153 KABELBAUM ZENCABLE HARNESS CENTRAL
TRALELEKTRONIK
ELECTRONIC
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
153 KABELBAUM ZENCABLE HARNESS CENTRAL
TRALELEKTRONIK
ELECTRONIC
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR
153 KABELBAUM ZENTRALELEKTRONIK
110 ELEKTROANLAGE RAHMEN
OBERWAGEN
413 KABELBAUM KONSOLE

CABLE HARNESS CENTRAL


ELECTRONIC
ELECTRICAL SYSTEM FRAME
UPPER CARRIAGE
CABLE HARNESS BRACKET
CABLE HARNESS CENTRAL
ELECTRONIC

x46

STECKDOSE BEGRENZUNGSLEUCHTEN SOCKET POSITION LAMP

32

X48.1

PLUG/SOCKET SIDE BRACKET LEFT

32

PLUG/SOCKET SIDE BRACKET LEFT

32

153 KABELBAUM ZENTRALELEKTRONIK

32

X52.1

STECKVERBINDUNG SEITENKONSOLE
LINKS
STECKVERBINDUNG SEITENKONSOLE
LINKS
STECKVERBINDUNG TASTATUR-MODUL
1
STECKVERBINDUNG TASTATUR-MODUL
2
STECKVERBINDUNG TASTATUR-MODUL
3
STECKVERBINDUNG SCHMIERANLAGE

PLUG/SOCKET LUBRICATION

32

X6.1

STECKVERBINDUNG

PLUG/SOCKET

32

X67.1

STECKVERBINDUNG BETANKUNGSANLAGE
STECKVERBINDUNG KLIMAANLAGE

PLUG / SOCKET FILLING PUMP

32

X72

PLUG/SOCKET AIR CONDITION

32

X72.1

STECKVERBINDUNG KLIMAANLAGE

PLUG/SOCKET AIR CONDITION

32

463 KABELBAUM LENKSTOCK- CABLE HARNESS SWITCH


SCHALTER
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR

X82

STECKVERBINDUNG UNTERWAGEN

PLUG/SOCKET UNDERCARRIAGE

32

X82.1

STECKVERBINDUNG UNTERWAGEN

PLUG/SOCKET UNDERCARRIAGE

32

x501
x502
x503

PLUG/SOCKET KEYBOARD-MODUL 1
PLUG/SOCKET KEYBOARD-MODUL 2
PLUG/SOCKET KEYBOARD-MODUL 3

123 KABELBAUM UNTERWAGEN


123 KABELBAUM UNTERWAGEN
510 KABELBAUM FAHRERHAUS

CABLE HARNESS LOWER


CARRIAGE
CABLE HARNESS LOWER
CARRIAGE
CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

x90

STECKVERBINDUNG RADIO

PLUG/SOCKET RADIO

32

x90.1

STECKVERBINDUNG RADIO LAUTSPRECHER


STECKVERBINDUNG GRID HEATER
CONTROLLER
STECKVERBINDUNG TANKSENSOR

PLUG/SOCKET RADIO LOUDSPEAKER

32

PLUG/SOCKET GRID HEATER CONTROLLER


PLUG/SOCKET TANK SENSOR

32

STECKVERBINDUNG DREHZAHLSENSOR
SCHWENKEN
DREHZAHLSENSOR SCHWENKEN
STECKVERBINDUNG DREHZAHLSENSOR
SCHWENKEN
DREHZAHLSENSOR SCHWENKEN
STECKVERBINDUNG ESX-CODIERUNG

PLUG/SOCKET SPEED SENSOR


SLEWING-GEAR

32

PLUG/SOCKET SPEED SENSOR


SLEWING-GEAR

32

300 ELEKTROANLAGE GETRIEBE

PLUG/SOCKET ESX-CODING

32

STECKVERBINDUNG CODIERUNGBREMSE
STECKVERBINDUNG ESX-CODIERUNG

PLUG/SOCKET BRAKE-CODING

32

PLUG/SOCKET ESX-CODING

32

XC3

STECKVERBINDUNG ESX-CODIERUNG

PLUG/SOCKET ESX-CODING

32

Xc5.1

STECKVERBINDUNG TASTATURMODUL

32

xc5.2

STECKVERBINDUNG TASTATURMODUL

32

PLUG/SOCKET CAN-COMMUNICATION

32

PLUG/SOCKET CAN-COMMUNICATION

32

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL
ELEKTRONIK
ELECTRONIC
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
510 KABELBAUM FAHRERHAUS CABLE HARNESS OPERATORS
CAB
433 KABELBAUM PODEST
CABLE HARNESS PLATFORM

PLUG/SOCKET CAN-COMMUNICATION

32

433 KABELBAUM PODEST

CABLE HARNESS PLATFORM


CABLE HARNESS BRACKET

XA17
XB2
XB35.2

XC1
XC16
XC2

xcan

STECKVERBINDUNG CANKOMMUNIKATION
XCAN2.2 STECKVERBINDUNG CANKOMMUNIKATION
XCAN2.2 STECKVERBINDUNG CANA
KOMMUNIKATION
xcan2.3
STECKVERBINDUNG CANKOMMUNIKATION
STECKVERBINDUNG CANKOMMUNIKATION
XE1
STECKVERBINDUNG SCHEINWERFER
VORN LINKS
XE12
STECKVERBINDUNG KENNZEICHENLEUCHTE
XE2
STECKVERBINDUNG SCHEINWERFER
RECHTS
XE2.1

32

ELECTRICAL SYSTEM TRANSMISSION GEAR

PLUG/SOCKET CAN-COMMUNICATION

32

413 KABELBAUM KONSOLE

PLUG/SOCKET CAN-COMMUNICATION

32

PLUG/SOCKET HEADLIGHT FRONT


LEFT
PLUG/SOCKET NUMBER PLATE LIGHT

32

PLUG/SOCKET HEADLIGHT RIGHT

32

153 KABELBAUM ZENTRALCABLE HARNESS CENTRAL


ELEKTRONIK
ELECTRONIC
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

32

32

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

BMK
XE22

ELECTRICAL SYSTEM

Deutsch

Englisch

Bgr

Ugr

3 - 75

Bezeichnung

Bezeichnung EN

STECKVERBINDUNG BLINKLEUCHTE
VORNE LINKS

PLUG/SOCKET TURN SIGNAL FRONT


LEFT

32

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE

STECKVERBINDUNG BLINKLEUCHTE
VORNE RECHTS
STECKVERBINDUNG ARBEITSSCHEINWERFER AUSLEGER
STECKVERBINDUNG SCHLEIFRINGKOERPER
STECKVERBINDUNG SCHLUSSLEUCHTE
LINKS
STECKVERBINDUNG SCHLUSSLEUCHTE
LINKS
STECKVERBINDUNG SCHLUSSLEUCHTE
RECHTS
STECKVERBINDUNG STANDLICHT LINKS
SCHWEIZ
STECKVERBINDUNG STANDLICHT LINKS
SCHWEIZ
STECKVERBINDUNG STANDLICHT
RECHTS SCHWEIZ
STECKVERBINDUNG STANDLICHT
RECHTS SCHWEIZ

PLUG/SOCKET TURN SIGNAL FRONT


RIGHT
PLUG/SOCKET WORKINGLIGHT BOOM

32

PLUG/SOCKET SLIP RING

32

PLUG/SOCKET TAIL LIGHT LEFT

32

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR

STECKVERBINDUNG ESX

xe23
XE23.1
XE3
XE32
XE5
XE5.5
XE6
xe7

XE8

32
PLUG/SOCKET TAIL LIGHT RIGHT
PLUG/SOCKET PARKING LIGHT LEFT
SWISS
PLUG/SOCKET PARKING LIGHT LEFT
SWISS
PLUG/SOCKET PARKING LIGHT RIGHT
SWISS
PLUG/SOCKET PARKING LIGHT RIGHT
SWISS

XE8.1
XESX

32

32

32
32

32
32

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

xg1
XR20.1

STECKVERBINDUNG POTENTIOMETER
MAX.GESCHWINDIG
STECKVERBINDUNG POTENTIOMETER
MAX.GESCHWINDIG
XR201
STECKVERBINDUNG POTENTIOMETER
MAX.GESCHWINDIG
XS1.1
STECKVERBINDUNG SEITENKONSOLEN
LI/RE
STECKVERBINDUNG SEITENKONSOLEN
LI/RE
XS20
STECKVERBINDUNG WARNBLINKANLAGE
XS7.7
STECKVERBINDUNG INITIATOR RCKFAHR-ALARM
XSTVZO STECKVERBINDUNG STANDLICHT
AUSRSTUNG
y1.4
HUBMAGNET MOTOR STOP

32
32
32
PLUG/SOCKET SIDE BRAKET LH/RH
PLUG/SOCKET SIDE BRAKET LH/RH

32
32
32

32

PLUG/SOCKET PARKING LIGHT ATTACHMENT


LIFTING MAGNET MOTOR STOP

32
95

HUBMAGNET MOTOR STOP

LIFTING MAGNET MOTOR STOP

32

Y10

PROPORTIONALVENTIL

PROPOTIONAL VALVE

32

PROPORTIONALVENTIL

PROPOTIONAL VALVE

23

Y113

MAGNETVENTIL VORSTEUERDRUCK

32

153 KABELBAUM ZENTRALELEKTRONIK


414 KABELBAUM INCHEINRICHTUNG
414 KABELBAUM INCHEINRICHTUNG
153 KABELBAUM ZENTRALELEKTRONIK
413 KABELBAUM KONSOLE

CABLE HARNESS CENTRAL


ELECTRONIC

CABLE HARNESS CENTRAL


ELECTRONIC
CABLE HARNESS BRACKET

463 KABELBAUM LENKSTOCK- CABLE HARNESS SWITCH


SCHALTER
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
336 EINSPRITZANLAGE ANINJECT.EQUIPMENT MOUNTBAUTEILE
ING PARTS
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
242 VENTILVERKETTUNG
VALVE INTERCONN.

Y131

MAGNETVENTIL OELKUEHLER

SOLENOID FOR PILOT CONTROL


PRESSURE
SOLENOID FOR PILOT CONTROL
PRESSURE
SOLENOID FOR OIL COOLER

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

Y16

MAGNETVENTIL FESTSTELLBREMSE

SOLENOID - PARKING BRAKE

32

MAGNETVENTIL FESTSTELLBREMSE

SOLENOID - PARKING BRAKE

23

123 KABELBAUM UNTERWAGEN


612 STEUERBLOCK

CABLE HARNESS LOWER


CARRIAGE
CONTROL BLOCK

Y18

MAGNETVENTIL BETRIEBSBREMSE

SOLENOID - BRAKE

32

MAGNETVENTIL BETRIEBSBREMSE

SOLENOID - BRAKE

23

Y201a

PROPORTIONALVENTIL FAHREN

PROPORTIONAL VALVE TRAVEL

32

Y201b

PROPORTIONALVENTIL FAHREN

PROPORTIONAL VALVE TRAVEL

32

Y202a

PROPORTIONALVENTIL PRATZEN

32

Y202b

PROPORTIONALVENTIL PRATZEN

Y203a

Y205a

PROPORTIONALVENTIL AUSLEGERZYLINDER
PROPORTIONALVENTIL AUSLEGERZYLINDER
PROPORTIONALVENTIL LOEFFELZYLINDER
PROPORTIONALVENTIL LOEFFELZYLINDER
PROPORTIONALVENTIL STIELZYLINDER

Y205b

PROPORTIONALVENTIL STIELZYLINDER

Y206a

PROPORTIONALVENTIL NACKENZYLINDER
PROPORTIONALVENTIL NACKENZYLINDER
PROPORTIONALVENTIL HAMMER/SCHERE
PROPORTIONALVENTIL HAMMER/SCHERE

PROPORTIONAL VALVE OUTRIGGER


STABILISERS
PROPORTIONAL VALVE OUTRIGGER
STABILISERS
PROPORTIONAL VALVE BOOM CYLINDER
PROPORTIONAL VALVE BOOM CYLINDER
PROPORTIONAL VALVE BACKHOE
CYLINDER
PROPORTIONAL VALVE BACKHOE
CYLINDER
PROPORTIONAL VALVE STICK CYLINDER
PROPORTIONAL VALVE STICK CYLINDER
PROPORTIONAL VALVE NECK CYLINDER
PROPORTIONAL VALVE NECK CYLINDER
PROPORTIONAL VALVE HAMMER/SHEARS
PROPORTIONAL VALVE HAMMER/SHEARS

MAGNETVENTIL VORSTEUERDRUCK

Y203b
Y204a
Y204b

Y206b
Y207a
Y207b

23

32
32
32
32
32
32
32
32
32
32
32

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
VALVE INTERCONN.

242 VENTILVERKETTUNG

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
212 SCHALTVENTIL
SHIFT VALVE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 76

BMK
Y209

ELECTRICAL SYSTEM

Deutsch

Englisch

Bgr

Ugr

WX210 - WX240

Bezeichnung

Bezeichnung EN

PROPORTIONALVENTIL SCHWENKEN
LINKS
PROPORTIONALVENTIL SCHWENKEN
LINKS
MAGNETVENTIL KRIECHGANG

PROPORTIONAL VALVE SWING LEFT

32

PROPORTIONAL VALVE SWING LEFT

22

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
030 SCHWENKPUMPE
SWING PUMP

SOLENOID VALVE - CRAWL GEAR

23

612 STEUERBLOCK

CONTROL BLOCK

MAGNETVENTIL KRIECHGANG

SOLENOID VALVE - CRAWL GEAR

32

MAGNETVENTIL 1. GANG

SOLENOID VALVE - 1.GEAR

23

123 KABELBAUM UNTERWAGEN


612 STEUERBLOCK

CABLE HARNESS LOWER


CARRIAGE
CONTROL BLOCK

MAGNETVENTIL 1. GANG

SOLENOID VALVE - 1.GEAR

32

PROPORTIONAL VALVE SWING RIGHT

32

PROPORTIONAL VALVE SWING RIGHT

22

y241

PROPORTIONALVENTIL PUMPE1

PROPORTIONAL VALVE FLOW SUMMATION (HAMMER)


PROPORTIONAL VALVE HAMMER
PRESSURE
PROPORTIONAL VALVE PUMP1

32

Y239.2

PROPORTIONALVENTIL SCHWENKEN
RECHTS
PROPORTIONALVENTIL SCHWENKEN
RECHTS
PROPORTIONALVENTIL FLOW SUMMATION (HAMMER)
PROPORTIONALVENTIL HAMMER DRUCK

PROPORTIONALVENTIL PUMPE1

PROPORTIONAL VALVE PUMP1

32

y242

PROPORTIONALVENTIL PUMPE2

PROPORTIONAL VALVE PUMP2

23

312 PROPORTIONALVENTIL

PROPORTIONALVENTIL PUMPE2

PROPORTIONAL VALVE PUMP2

32

Y290

MAGNETVENTIL VORSTEUERDRUCK
FAHREN
MAGNETVENTIL VORSTEUERDRUCK
FAHREN
MAGNETVENTIL NACHSPEISUNG FAHRMOTOR
MAGNETVENTIL NACHSPEISUNG FAHRMOTOR
MAGNETVENTIL SCHWENKWERKBREMSE
MAGNETVENTIL SCHWENKWERKBREMSE
MAGNETVENTIL GREIFERDREHWERK
MAGNETVENTIL GREIFERDREHWERK

SOLENOID FOR PILOT CONTROL


PRESSURE TRAVEL
SOLENOID FOR PILOT CONTROL
PRESSURE TRAVEL
FEEDING VALVE DRIVING MOTOR

32
23

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
232 MAGNETVENTIL
SOLENOID VALVE

23

060 SPEISEDRUCKVENTIL

FEED. PRESS. VALVE

FEEDING VALVE DRIVING MOTOR

32

253 KABELBAUM MOTOR

CABLE HARNESS MOTOR

SOLENOID - SLEWING-GEAR BRAKE

23

242 VENTILVERKETTUNG

VALVE INTERCONN.

SOLENOID - SLEWING-GEAR BRAKE

32

SOLENOID VALVE - GRAB ROTATOR


SOLENOID VALVE - GRAB ROTATOR

23
32

MAGNETVENTIL GREIFERDREHWERK

SOLENOID VALVE - GRAB ROTATOR

23

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
232 MAGNETVENTIL
SOLENOID VALVE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
232 MAGNETVENTIL
SOLENOID VALVE

MAGNETVENTIL GREIFERDREHWERK

SOLENOID VALVE - GRAB ROTATOR

32

MAGNETVENTIL FREQUENZUMSCHALTUNG
MAGNETVENTIL FREQUENZUMSCHALTUNG
MAGNETVENTIL UMSCHALTUNG HAMMER/SCHERE
MAGNETVENTIL ABSTUETZUNG VORNE
LINKS
MAGNETVENTIL ABSTUETZUNG VORNE
LINKS
MAGNETVENTIL ABSTUETZUNG VORNE
RECHTS
MAGNETVENTIL ABSTUETZUNG VORNE
RECHTS
MAGNETVENTIL ABSTUETZUNG HINTEN
LINKS
MAGNETVENTIL ABSTUETZUNG HINTEN
LINKS
MAGNETVENTIL ABSTUETZUNG HINTEN
RECHTS
MAGNETVENTIL ABSTUETZUNG HINTEN
RECHTS
MAGNETVENTIL PENDELACHSBLOCKIERUNG
MAGNETVENTIL PENDELACHSBLOCKIERUNG
KRAFTVERSTAERKUNG

SOLENOID VALVE - FREQUENCY


CHANGE-OVER
SOLENOID VALVE - FREQUENCY
CHANGE-OVER
SOLENOID VALVE - SWITCH OVER
HAMMER/SHEARS
SOLENOID VALVE - STABILZER FRONT
LEFT
SOLENOID VALVE - STABILZER FRONT
LEFT
SOLENOID VALVE - STABILZER FRONT
RIGHT
SOLENOID VALVE - STABILZER FRONT
RIGHT
SOLENOID VALVE - STABILZER REAR
LEFT
SOLENOID VALVE - STABILZER REAR
LEFT
SOLENOID VALVE - STABILZER REAR
RIGHT
SOLENOID VALVE - STABILZER REAR
RIGHT
SOLENOID VALVE - AXLE BLOCK

32

SOLENOID VALVE - AXLE BLOCK

KRAFTVERSTAERKUNG
ELEKTROMAGNETKUPPLUNG KLIMAANLAGE

y21.2

y21.4

Y212

Y239.1

y295

y35

y37.1

y37.2

Y39.3

Y39.9
y48.1

y48.2

Y48.3

Y48.4

Y62

y63

Y72

32
23

32
32
23
32

123 KABELBAUM UNTERCABLE HARNESS LOWER


WAGEN
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
030 SCHWENKPUMPE
SWING PUMP
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
312 PROPORTIONALVENTIL
PROPORTIONAL VALVE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
PROPORTIONAL VALVE

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER
CARRIAGE
182 WEGEVENTIL
CONTROL VALVE
123 KABELBAUM UNTERWAGEN
182 WEGEVENTIL

CABLE HARNESS LOWER


CARRIAGE
CONTROL VALVE

123 KABELBAUM UNTERWAGEN


123 KABELBAUM UNTERWAGEN
182 WEGEVENTIL

CABLE HARNESS LOWER


CARRIAGE
CABLE HARNESS LOWER
CARRIAGE
CONTROL VALVE

123 KABELBAUM UNTERWAGEN


182 WEGEVENTIL

CABLE HARNESS LOWER


CARRIAGE
CONTROL VALVE

23

123 KABELBAUM UNTERWAGEN


612 STEUERBLOCK

CABLE HARNESS LOWER


CARRIAGE
CONTROL BLOCK

POWER BOOSTER

23

232 MAGNETVENTIL

SOLENOID VALVE

POWER BOOSTER

32

ELECTR. MAGNETCLUTCH AIR CONDITION

32

113 KABELBAUM OBERWAGEN CABLE HARNESS UPPER


CARRIAGE
253 KABELBAUM MOTOR
CABLE HARNESS MOTOR

23
32
32
23
32
23
32

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 77

Connector pin assignment table for connector X33A


<--- INTERN CU

Bemerkung

Ziel 2

Zentralektronik

Ziel 1
A100X3a:7

ESX

XESX:24

X33D:18

Frequenzumschaltung

S39.3:1

X12A:15

X10

FA.6:2

Sicherungsleiste FA
ESX

XESX:41

Grenzlastregler

X33D:29
A10X1:2

ESX

XESX:63

X33D:38

ESX

XESX:62

X33D:30

ESX

XESX:18

X33D:39

ESX

XESX:47

X33D:37

ESX

XESX:46

X33D:36

X10

FA.6:2

Sicherungsleiste FA
Zentralektronik

A100X6:8

Grenzlastregler

A10X1:7

Zentralektronik
Sicherungsleiste FA

A100X2a:2
X10

FA.16:2

A100X6:14

Splice 2

ESX

XESX:14

X33D:28

ESX

XESX:36

X33D:35

Zentralektronik

Zentralektronik
Tanksensor

A100X1:13
A100X6:14

Zentralektronik
Sicherungsleiste FA
Tanksensor

V67.1:K
A100X2a:13

X10
A100X6:14

X33A

X33A:2 - Y35:1

Y35:1

X33A

X33A:3 - Y39.3:1

Y39.3:1

X33A

X33A:4 - S290:1

S290:1

X33A

X33A:5 - S290:2

X33A

X33A:6 - Y10:1

Y290:1

10

X33A

X33A:10 - Y242:1

Y242:1

11

X33A

X33A:11 - Y241:1

12

X33A

13

X33A

14

X33A

X33A:14 - R14:1

15

X33A

X33A:15 - S15:1

16

X33A

17

X33A

18

X33A

19

X33A

20

X33A

X33A:20 - XE3:1

XE3:1

21

X33A

X33A:21 - XB2:1

XB2:1

Tanksensor

22

X33A

X33A:22 - XB2:3

XB2:3

Tanksensor

X33A

29

X33A

30

X33A

31

X33A

32

K5.1:87

Zentralektronik

A100X1:8

Zentralektronik

A100X3a:9

ESX

XESX:3

X33D:1

ESX

XESX:8

X33D:40
A100X7:4

X33A:38 X33D:1
X33A:39 X33D:40
A100X7:4 X33A:40

Proportionalventil
Abschaltung Vorsteuerung Arbeitshydraulik

S113.4:1

28

Splice 1

Druckschalter Vorsteuerdruck Fahren

X31.O2

X33A:9 S113.4:1

X33A

A100X3a:1 X33A:32
Splice 1 X33A:33
X33A:34 K5.1:87
A100X1:8 X33A:35
A100X3a:9 X33A:36

X33A:4

Y10:1

X33A:8 - Y290:1

27

A100X3a:1

S290:2

X33A

X33A

Zentralektronik

Druckschalter Vorsteuerdruck Fahren

X33A

26

A100X3a:13

X33A:5

X33A

Zentralektronik

Schwenkbremse
Frequenzumschaltung

X33A

X12A:12

Hubkraftverstrker

X33A:7 - Y113:1

25

S36:1

Y63:1

Bemerkung

X33A

24

X33A:27 X33D:33
X33A:28 X33D:34
X33A :29 X12A:12
A100X3a:13 X33A:30

X33A:1 - Y63:1

Ziel 2

V67.1:K

X33D:34

Zentralelektronik

A100X6:8 X33A:13
A10X1:7 X33A:14
A100X2a:2 X33A:15
FA.16:2 X33A:16
Splice 2 X33A:17
X33A:18 X33D:28
X33A:19 X33D:35
A100X1:9 X33A:20
V67.1:K X33A:21
A100X2a:13 X33A:22

X33A

X33A

XESX:25

FA.11:2

FA.6:2 - X33A:12

Ziel 1

23

ESX

Sicherungsleiste FA

X33A:5 X33D:29
A10X1:2 X33A:6
X33A:7 X33D:38
X33D:30 X33A:8
X33A:9 X33D:39
X33A:10 X33D:37
X33D:36 X33A:11

Stecker Kennzeichg.

V67.1:K X33A:24

X33D:33

A100X3a:4

FA.6:2 - X33A:4

PIN

FA.5:2 - X33A:23

XESX:3

Zentralektronik

A100X3a:7 X33A:1
X33A:2 X33D:18
X12A:15 X33A:3

EXTERN Maschine--->

FA.5:2

ESX

Schater Rundumleuchte Tank

Kennzeichg.

S0000531-en

X33A:12 S113.4:2
X33A:13 X52.1:3

X33A:16 X52.1:1
X33A:17 B35.2:1
X33A:18 B35.2:4
X33A:19 B35.2:3

X33A:23 X67.1:2
X33A:24 X67.1:3

Y113:1

Abschaltung Vorsteuerung Fahren


X33A:12

Proportionalventil Pumpe 2

Y241:1
S113.4:2

Proportionalventil Pumpe 1
X33A:9

X52.1:3
R14:1

Druckschalter Vorsteuerdruck
Arbeitshydraulik

Druckschalter Vorsteuerdruck
Arbeitshydraulik
Schmierpumpe

X31.O2

S15:1

Temperatur Hydraulikl
Hydraulikl Filter

X52.1:1

Schmierpumpe

B35.2:1

Initiator Schwenkbremse

B35.2:4

Initiator Schwenkbremse

B35.2:3

Initiator Schwenkbremse
X31.A

Arbeitsscheinwerfer Ausleger

X67.1:2

K67:87

Betankungsanlage

X67.1:3

V67.2:K

Betankungsanlage

Y37.1:1

X31.O2

Greiferdrehwerk Links

Y37.2:1

X31.O2

Greiferdrehwerk Rechts

E36.1:1

X12.31

Rundumleuchte Tank

X33A:30 - H7:1

H7:1

X31.O2

Horn

X33A

X33A:32 - XE23:1

XE23:1

XE23:2

Blinklicht Rechts Vorn

33

X33A

X33A:33 - XE2:2

XE2:2

XE2:1

Standlicht Rechts

34

X33A

X33A:34 XE2:4

XE2:4

XE2:1

Fernlicht Rechts

35

X33A

X33A:35 - XE2:3

XE2:3

XE2:1

Fahrlicht Rechts

36

X33A

37

X33A

38

X33A

XC33A:38 B35.2:2

B35.2:2

39

X33A

X33A:39 - B74:1

B74:1

Sensor Druck Ausleger

40

X33A

X33A:40 - B74:3

B74:3

Sensor Druck Ausleger

X33A:27 Y37.1:1
X33A:28 Y37.2:1
X33A:29 E36.1:1

Initiator Schwenkbremse

frei

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 78

ELECTRICAL SYSTEM

WX210 - WX240

Connector pin assignment table for connector X33B


<--- INTERN CU

Bemerkung
Zentralelektronik

Ziel 2

Ziel 1

Kennzeichg.

PIN

A100X3a:4

Splice2

Splice2 - X33B:1

X33B

X33B:1 - XE6:2

XE6:2

Schlulicht Rechts

X33B

X33B:2 - XE6:4

XE6:4

Blinklicht Rechts Hinten

X33B

X33B:3 - XE6:3

XE6:3

X33B

X33B:4 - XE6.5:1

XE6.5:1

X33B

X33B:5 - K1.5:86

K1.5:86

X31.O

Startrelais

X33B

X33B

X33B

X33B:8 - B10.1:A

B10.1:A

X101:3

Pick-Up

X33B

X33B:9 - R10.3:1

R10.3:1

X101:3

Temperaturfhler Ladeluft

10

X33B

X33B:10 Y131:1

Y131:1

X101:6

Proportionalventil lkhler Lftersteuerung

11

X33B

X33B:11 - M10:5

M10:5

Drehzahlverstellmotor

12

X33B

X33B:12 - M10:1

M10:1

Drehzahlverstellmotor

13

X33B

X33B:13 - M10:2

M10:2

Drehzahlverstellmotor

14

X33B

X33B:14 - M10:3

M10:3

Drehzahlverstellmotor

15

X33B

X33B:15 - M10:4

M10:4

Drehzahlverstellmotor

16

X33B

X33B:16 S12:WK

S12:WK

Druckschalter Motorl

17

X33B

Zentralelektronik

A100X3a:1

Zentralelektronik

A100X7:16

Schalter Nebelschlulicht

S55:1

X12A:13

Sicherungsleiste FA

FA.2:2

K1:87

Zentralelektronik

A100X2a:24

Grenzlastregler

A10X1:24

Grenzlastregler

A10X1:6

Grenzlastregler

A10X1:18

Zentralelektronik

A100X3a:15

Zentralelektronik

A100X3a:16

Zentralelektronik

A100X3a:17

Zentralelektronik

A100X3a:18

Zentralelektronik

A100X3a:19

Zentralelektronik

A100X2a:21

Sicherungsleiste FA

A100X3a:1 X33B:2
A100X7:16 X33B:3
X12A:13 X33B:4
X33B:5 - K1:87

A100X2a:24 X33B:7
A10X1:24 X33B:8
A10X1:6 X33B:9
A10X1:18 X33B:10
A100X3a:15 X33B:11
A100X3a:16 X33B:12
A100X3a:17 X33B:13
A100X3a:18 X33B:14
A100X3a:19 X33B:15
A100X2a:21 X33B:16

Stecker Kennzeichg.

Ziel 1

X33B

X33B:18 B13.1:B

B13.1:B

XS1.1:3

FA.1:2

FA.1:2 - X33B:19

19

X33B

X33B:19 - Y1.4:A

Y1.4:A

X30.2

FA.23:2

20

X33B

X33B:20 - Y1.4:B

Y1.4:B

Motor Stop Magnet

Y295:1

X31.O

Proportionalventil Nachspeisung
Fahrmotor

K1.7:87

F20:2

Kaltstartanlage Grid Heater

A100X7:9
XA17:3

FA.23:2 X33B:20
A100X7:9 X33B:21
XA17:3 X33B:22

21

X33B

22

X33B

X33B:21 Y295:1
X33B:22 K1.7:87

Sicherungsleiste FA

X10

FA.8:2

FA.8:2 - X33B:23

23

X33B

X33B:23 - XG1:3

XG1:3

Sicherungsleiste FA

FA.21:2

K20.3:85

X33B:24 K20.3:85

24

X33B

X33B:24 B116:1

B116:1

25

X33B

XS1.1:3

FA.1:2

FA.1:2 - X33B:26

26

X33B

X19:5

X72:2

X72:2 - X33B:27

27

X33B

28

X33B

Zentralelektronik

A100X6:19

Sicherungsleiste FA

FA.22:2

K20.3:87

Relais Filter Heater

K20.3:30

K20.4:87

Grid Heater Controller

XA17:4

Grid Heater Controller

XA17:10

Grid Heater Controller

XA17:6

Sicherungsleiste FA

X30.2

FA.17:2

Relais Standheizung

X33B:36

K31:85

Relais Standheizung

X33B:35

K31:86

Zentralelektronik

A100X7:5

FA.27:2

A31.1:2

X12B:11

Schaltuhr Heizung

A31.1:8

X12B:12

Schaltuhr Heizung

A31.1:12

X12B:13

Schaltuhr Heizung

Bremslicht Rechts
Nebelschlulicht rechts

18

Grid Heater Controller

Geblse

Bemerkung

A10X1:5 X33B:18

Zentralelektronik

Zndschlo

Ziel 2

A10X1:5

Grenzlastregler
Zndschlo

EXTERN Maschine--->

A100X6:19 X33B:28
X33B:29 K20.3:87
X33B:30 K20.4:87
XA17:4 X33B:31
XA17:10 X33B:32
XA17:6 X33B:33
FA.17:2 X33B:34
X33B:35 K31:85
X33B:36 K31:86
FA.27:2 X33B:37
X12B:11 X33B:38
X12B:12 X33B:39
X12B:13 X33B:40

X33B:26 K10.1:L
X33B:27 X72.1:1
X33B:28 S15.1:1

X101:4

Temperaturfhler Khlwasser
Motor Stop Magnet

Generator "15"
X31.O

K10.1:L

Temperaturfhler Grid Heater

Power Relais

X72.1:1

S72.1:bl

S15.1:1

X31.O

Druckschalter Verdichter
berwachung Luftfilter

29

X33B

X33B:29 - R19:A

R19:A

X31.O

Filter Heater

30

X33B

X33B:30 - R21:A

R21:A

X31.O

Filter Heater

31

X33B

X33B:31 - XG1:2

XG1:2

32

X33B

33

X33B

34

X33B

35

X33B

36

X33B

37

X33B

38

X33B

39

X33B

40

X33B

X33B:32 B13.1:A
X33B:33 K1.7:86

X33B:37 K10.1:B

Generator "D+"

B13.1:A
K1.7:86

K10.1:B

Temperatur Khlwasser
X31.O

Relais Grid Heater

Power Relais

frei

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 79

Connector pin assignment table for connector X33C


<--- INTERN CU
Bemerkung
Sicherungsleiste FA
CAN-Stecker

Ziel 2

Ziel 1

Kennzeichg.

PIN

Stecker

Kennzeichg.

Ziel 1

Ziel 2

Bemerkung

X30.2
X12CAN:3

FA.29:2
FA.15:2

FA.29:2 - X33C:1
FA.15:2 - X33C:2
A100X3a:5 X33C:3
Splice 2 - X33C:4
X33C:5 - A10X4:C
X33C:6 - A10X4:D
X12CAN:1 - X33C:7
X12CAN:2 - X33C:8

1
2

X33C
X33C

X33C:1 - X103.1:2
X33C:2 - X103:5

X103.1:2
X103:5

S20:30
X503:9

Warnblinken
Tastenmodul C5.3

X33C

X33C:3 - X103.1:4

X103.1:4

S20:R

Warnblinken

4
5
6
7
8

X33C
X33C
X33C
X33C
X33C

X33C:4 - XE12:2
X33C:5 - X103:1
X33C:6 - X103:2
X33C:7 - X103:3
X33C:8 - X103:4

XE12:1
X103:1
X103:2
X103:3
X103:4

XE12:2
X503:7
X503:8
X503:7
X503:8

Kennzeichenleuchte
Tastenmodul C5.3
Tastenmodul C5.3
Tastenmodul C5.3
Tastenmodul C5.3
Lenkstockschalter Fernlicht.

Zentralelektronik
Zentralelektronik
Diagnose-Steckdose
Diagnose-Steckdose
Tastenmodul C5.1
Tastenmodul C5.1
Massepunkt Podestplatte
Sicherungsleiste FA
Schalter Nebelschlusslicht

A100X3a:5
A100X3a:4

C5.1:7
C5.1:8

Splice 2
A10X4:C
A10X4:D
X12CAN:1
X12CAN:2

X31.P

K5.1:86

X33C:9 - K5.1:86

X33C

X33C:9 - X103.1:1

X103.1:1

S23:56a

FA.11:2

K5.1:87

X33C:10 - K5.1:87

10

X33C

X33C:10 - XE1:4

XE1:4

XE1:1

Fernlicht Links

S55:1

X12A:13

X12A:13 - X33C:11

11

X33C

X33C:11 - XE5.5:1

XE5.5:1

XE5:5

Nebelschlusslicht Links

12

X33C

X33C:12 - XE1:3

XE1:3

XE1:1

Fahrlicht Links

13

X33C

X33C:13 - Splice 2

Splice 2

siehe unten siehe unten

14

X33C

X33C:14 - Splice 1

Splice 1

siehe unten siehe unten

15

X33C

X33C:15 - XE5:3

XE5:3

XE5:1

Bremslicht Links

16

X33C

X33C:16 - S18.2:1

S18.2:1

X31.P

Druckschalter Betriebsbremse

17
18

X33C
X33C

X33C:18 - S18:1

S18:1

X33C:19

19

X33C

X33C:19 - S18:2

S18:2

X33C:18

20

X33C

X33C:20 - S18.1:1

S18.1:1

X31.O

Druckschalter Mindestbremsdruck

21

X33C

X33C:21 - S17:1

S17:1

X31.O

Druckschalter Lenkung

22

X33C

X33C:22 - S62.1:1

S62.1:1

X31.O

Druckschalter Pendelachsblockierung

23
24

X33C
X33C

25

X33C

X33C:25 - XE32:1

XE32:1

X82:1

Druckschalter Festellbremse

Zentralelektronik

A100X1:8

Zentralelektronik

A100X3a:2

Zentralelektronik

A100X3a:3

Zentralelektronik

A100X7:16

Zentralelektronik

A100X6:20

Leuchte H16
Sicherungsleiste FA

H16:1
X10

X12B:5
FA.8:2

Zentralelektronik

A100X6:2

Zentralelektronik

A100X2a:5

Zentralelektronik

A100X2a:4

Zentralelektronik

A100X2a:22

Zentralelektronik

A100X2a:3

Zentralelektronik

A100X7:7

Zentralelektronik

A100X2a:11

Zentralelektronik

A100X6:18

Zentralelektronik

A100X6:14

Zentralelektronik

A100X1:8 X33C:12
A100X3a:2 X33C:13
A100X3a:3 X33C:14
A100X7:16 X33C:15
A100X6:20 X33C:16
X12B:5 - X33C:17
FA.8:2 - X33C:18
A100X6:2 X33C:19
A100X2a:5 X33C:20
A100X2a:4 X33C:21
A100X2a:22 X33C:22

A100X2a:3 X33C:25
A100X7:7 X33C:26
A100X2a:11 X33C:27
A100X6:18 X33C:28
Splice 1 - X33C:29
A100X3a:10 X33C:30
A100X7:8 X33C:31

Druckschalter Bremslicht
Druckschalter Bremslicht

26

X33C

X33C:26 - XE32:2

XE32:2

X82:2

Proportionalventil Kriechgang

27

X33C

X33C:27 - XE32:3

XE32:3

X82:3

Geschwindigkeitssensor Fahren

28

X33C

X33C:28 - XE32:4

X82:4

Geschwindigkeitssensor Fahren

29

X33C

X33C:29 - XE32:5

X82:5

Geschwindigkeitssensor Fahren

30

X33C

X33C:30 - XE32:6

X33C:28 XE32:4
X33C:29 XE32:5
X33C:30 XE32:6
X33C:31 XE32:7
X33C:32 XE32:8

X82:6

Proportionalventil 1. Gang

X82:7

Proportionalventil Pendelachsblockierung

X82:8

Proportionalventil Feststellbremse

31

X33C

X33C:31 - XE32:7

XC16:3

XC16:2

XC16:2 - X33C:32

32

X33C

X33C:32 - XE32:8

S48.1

X48.1:3

X48.1:3 - X33C:33

33

X33C

X33C:33 - XE32:9

X33C:33 XE32:9

X82.1:1

Proportionalventil Absttzung/Planierschild

S48.2

X48.1:4

X48.1:4 - X33C:34

34

X33C

X33C:34 - XE32:10

X33C:34 XE32:10

X82.1:2

Proportionalventil Absttzung/Planierschild

S48.3

X48.1:5

X48.1:5 - X33C:35

35

X33C

X33C:35 - XE32:11

X33C:35 XE32:11

X82.1:3

Proportionalventil Absttzung/Planierschild

S48.4

X48.1:6

X48.1:6 - X33C:36

36

X33C

X33C:36 - XE32:12

X33C:36 XE32:12

X82.1:4

Proportionalventil Absttzung/Planierschild

37

X33C

X33C:37 - XE32:13

X82:13

Reserve

38

X33C

X33C:38 - XE32:14

X82:14

Reserve

A100X2a:8

A100X2a:8 X33C:39

39

X33C

X33C:39 - X103.1:3

S20:30b

Warnblinken

K18.2:87

K18.2:87 - X33C:40

40

X33C

X33C:40 - Y18:1

X33C:14 - Splice 1

Ein

Splice 1

Splice 1 - XE1:2

XE1:2

XE1.1

Standlicht Links

X33C:14 - Splice 1

Ein

Splice 1

Splice 1 - XE5:2

XE5:2

XE5:1

Schlulicht Links

X33C:14 - Splice 1

Ein

Splice 1

Splice 1 - XE7:CH

XE7:CH

X33C:14 - Splice 1

Ein

Splice 1

Splice 1 XSTVZO:1

XSTVZO:1

X33C:13 - Splice 2

Ein

Splice 2

Splice 2 - XE5:4

XE5:4

XE5:1

Blinklicht Links Hinten

X33C:13 - Splice 2

Ein

Splice 2

Splice 2 - XE22:2

XE22:2

XE22:2

Blinklicht Links Vorne

A100X7:8

Zentralelektronik
Feststell-/ Betriebsbremse

Splice 1
A100X3a:10

Zentralelektronik
Wippschalter Feststellbremse
Wippschalter Absttzung/
Planierschild
Wippschalter Absttzung/
Planierschild
Wippschalter Absttzung/
Planierschild
Wippschalter Absttzung/
Planierschild

EXTERN Maschine--->

K16.1:87

X33C:37 XE32:13
X33C:38 XE32:14
X33C:39 X103.1:3
Y18:1

X31.P

Betriebsbremse

Standlicht Links Einzeln


Standlicht Ausleger

frei

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 80

ELECTRICAL SYSTEM

WX210 - WX240

Connector pin assignment table for connector X33D


<--- INTERN CU

EXTERN Maschine--->

Bemerkung

Ziel 2

Ziel 1

Kennzeichg.

PIN

Stecker

Kennzeichg.

Ziel 1

Initiator Schwenken

B35.2:2

X33A:38

X33A:38 - X33D:1

X33D

X33D:1 - XESX:30

XESX:30

Ziel 2

ESX

Bemerkung

Relais ESX

X33D:27

K-ESX:87

X33D:2 - K-ESX:87

X33D

X33D:2 - XESX:28

XESX:28

ESX

Sicherungsleiste FA

FA14:1

FA.13:2

FA.13:2 - X33D:3

X33D

X33D:3 - XESX:54

XESX:54

ESX

Sicherungsleiste FA

X10

FA.14:2

FA.14:2 - X33D:4

X33D

X33D:4 - XESX:56

XESX:56

ESX

Sicherungsleiste FA

X10

FA.14:2

FA.14:2 - X33D:5

X33D

X33D:5 - XESX:57

XESX:57

ESX

Sicherungsleiste FA

X10

FA.14:2

FA.14:2 - X33D:6

X33D

X33D:6 - XESX:58

XESX:58

ESX

Sicherungsleiste FA

X10

FA.14:2

FA.14:2 - X33D:7

X33D

X33D:7 - XESX:59

XESX:59

ESX

Sicherungsleiste FA

X10

FA.14:2

FA.14:2 - X33D:8

X33D

X33D:8 - XESX:60

XESX:60

ESX

XS1.1:12

XS1.1:13

XS1.1:13 - X33D:9

X33D

X33D:9 - XESX:16

XESX:16

ESX

Abschaltung Vorsteuerung
Abschaltung Vorsteuerung

XS1.1:12

XS1.1:14

XS1.1:14 - X33D:10

10

X33D

X33D:10 - XESX:34

XESX:34

ESX

Sicherungsleiste FA

X33D:12

FA.4:2

FA.4:2 - X33D:11

11

X33D

X33D:11 - XESX:1

XESX:1

ESX

Sicherungsleiste FA

X33D:11

FA.4:1

X33D:12 - FA.4:1

12

X33D

X33D:12 - B213:1

B213:1

A100X7:4

A100X7:4 X33D:13

13

X33D

X33D:13 - SPL1

SPL1

14

X33D

15

X33D

16

X33D

17

X33D

18

X33D

X33D:18 - XESX:24

XESX:24

ESX

19

X33D

X33D:19 - XESX:27

XESX:27

ESX

Zentralelektronik

Proportionalventil
Schwenkbremse

Y35:1

X33A:2

Zentralelektronik

A100X3a:20

Zentralelektronik

A100X3a:21

X33A:2 - X33D:18
A100X3a:20 X33D:19
A100X3a:21 X33D:20

Sensor Winkel Schwenkpumpe


siehe unten siehe unten

20

X33D

X33D:20 - XESX:26

XESX:26

ESX

Diagnose-Steckdose

A7.3X4:4

A7.3X4:4 - X33D:21

21

X33D

X33D:21 - A61X1:1

A61X1:1

Pedal Fahren

Diagnose-Steckdose

A7.3X4:5

A7.3X4:5 - X33D:22

22

X33D

X33D:22 - A61X1:2

A61X1:2

Pedal Fahren

FA.15:2

FA.15:2 - X33D:23

23

X33D

X33D:23 - A61X1:3

A61X1:3

Pedal Fahren

X31:P

X31:P - X33D:24

24

X33D

X33D:24 - A61X1:4

A61X1:4

A10X1:4

A10X1:4 - X33D:25

25

X33D

X33D:25 - Y207a:1

Y207a:1

X31.O

Proportionalventil Hammer/Schere

X31.O

Proportionalventil Hammer/Schere

CAN-Stecker

X12CAN:3

Massepunkt Podestplatte
Grenzlastregler
Grenzlastregler

Pedal Fahren

A10X1:3

A10X1:3 - X33D:26

26

X33D

X33D:26 - Y207b:1

Y207b:1

Relais ESX

X33D:2

K-ESX:30

X33D:27 - KESX:30

27

X33D

X33D:27 - XC1:1

XC1:1

Initiator Schwenken

B35.2:4

X33A:18

X33A:18 - X33D:28

28

X33D

X33D:28 - XESX:14

XESX:14

ESX

S290:2

X33A:5

X33A:5 - X33D:29

29

X33D

X33D:29 - XESX:41

XESX:41

ESX

Y290:1

X33A:8

X33D:30 - X33A:8

30

X33D

X33D:30 - XESX:62

XESX:62

ESX

31

X33D

X33D:31 - S39.9:1

S39.9:1

Druckschalter Tankrcklauf Schere

32

X33D

X33D:32 - Y39.9:1

Y39.9:1

Proportionalventil Umschaltung
Hammer/Schere

Druckschalter berwachung Vorsteuerdruck


Proportionalventil
Abschaltung Vorsteuerung Fahren
Zentralelektronik

A100X6:13

Zentralelektronik

A100X1:10

Proportionalventil
Greifdrehwerk Links
Proportionalventil
Greifdrehwerk Rechts
Initiator Schwenken
Proportionalventil
Pumpe 1
Proportionalventil
Pumpe 2
Proportionalventil
Vorsteuerung Arbeitshydraulik
Druckschalter berwachung Vorsteuerdruck
Sensor Druck Ausleger

A100X6:13 X33D:31
A100X1:10 X33D:32

Code-Control

Y37.1:1

X33A:27

X33A:27 - X33D:33

33

X33D

X33D:33 - XESX:3

XESX:3

ESX

Y37.2:1

X33A:28

X33A:28 - X33D:34

34

X33D

X33D:34 - XESX:25

XESX:25

ESX

B35.2:3

X33A:19

X33A:19 - X33D:35

35

X33D

X33D:35 - XESX:36

XESX:36

ESX

Y241:1

X33A:11

X33D:36 - X33A:11

36

X33D

X33D:36 - XESX:46

XESX:46

ESX

Y242:1

X33A:10

X33A:10 - X33D:37

37

X33D

X33D:37 - XESX:47

XESX:47

ESX

Y113

X33A:7

X33A:7 - X33D:38

38

X33D

X33D:38 - XESX:63

XESX:63

ESX

S113.4:1

X33A:9

X33A:9 - X33D:39

39

X33D

X33D:39 - XESX:18

XESX:18

ESX

B74:1

X33A:39

X33A:39 - X33D:40

40

X33D

X33D:40 - XESX:8

XESX:8

ESX

X33D:13 - SPL1
X33D:13 - SPL1
X33D:13 - SPL1
X33D:13 - SPL1
X33D:13 - SPL1
X33D:13 - SPL1

Ein
Ein
Ein
Ein
Ein
Ein

Splice 1
Splice 1
Splice 1
Splice 1
Splice 1
Splice 1

SPL1 - B10:3
SPL1 - B210:3
SPL1 - B211:3
SPL1 - B212:3
SPL1 - B213:3
SPL1 - B239:3

B10:3
B210:3
B211:3
B212:3
B213:3
B239:3

Sensor Fahrdruck
Sensor Druck Pumpe 2
Sensor Druck Pumpe 1
Sensor Druck Schwenkpumpe
Sensor Winkel Schwenkpumpe
Sensor Last

frei

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRICAL SYSTEM

3 - 81

Connector pin assignment table for connector X33E


<--- INTERN CU

Bemerkung
Proportionalventil
Fahren Vorwrts
Proportionalventil
Fahren Rckwrts

EXTERN Maschine--->

Ziel 2

Ziel 1

Kennzeichg.

PIN

Stecker

Kennzeichg.

Ziel 1

Y201.A:1

X33E:3

X33E:1 - X33E:3

X33E

X33E:1 - XESX:45

XESX:45

Y201.B:1

X33E:4

X33E:2 - X33E:4

X33E

X33E:2 - XESX:42

XESX:42

ESX

XESX:45

X33E:1

X33E:1 - X33E:3

X33E

X33E:3 - Y201.A:1

Y201.A:1

ESX

XESX:42

X33E:2

X33E:2 - X33E:4

X33E

X33E:4 - Y201.B:1

Y201.B:1

X33E:7
X33E:8
X33E:5
X33E:6

K202.A:30
K202.B:30
K202.A:87
K202.B:87

X33E:5 - K202.A:30
X33E:6 - K202.B:30
X33E:7 - K202.A:87
X33E:8 - K202.B:87

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E
X33E

X33E:5 - XESX:50
X33E:6 - XESX:43
X33E:7 - Y202.A:1
X33E:8 - Y202.B:1

XESX:50
XESX:43
Y202.A:1
Y202.B:1

Relais Pratzen
Relais Pratzen
Relais Pratzen
Relais Pratzen

Ziel 2

Bemerkung
ESX
ESX
Proportionalventil Fahren
Vorwrts
Proportionalventil Fahren
Rckwrts
ESX
ESX
Proportionalventil Pratzen
Proportionalventil Pratzen

Connector pin assignment table for connector X33P


<--- INTERN CU

Bemerkung
Sternpunkt "X30"
Sternpunkt "X10"

Sternpunkt "X10"
Sternpunkt "X10"

Ziel 2

Ziel 1
X33P:R X30.2
X33P:S X10
X33P:U X10
X33P:U X10

EXTERN Maschine--->

Kennzeichg.

PIN

Stecker

Kennzeichg.

Ziel 1

X33P:R - X30.2

X33P

X33P:R - K10.1:30

K10.1:30

Ziel 2

Bemerkung
Power Relais

X33P:S - X10

X33P

X33P:S - K10.1:87

K10.1:87

Power Relais

X33P

X33P:U - X10

X33P

X33P:U - K10.1:87

K10.1:87

Power Relais

X33P:U - X10

X33P

X33P:U - K10.1:87

K10.1:87

Power Relais

V
W
X
Y
Z

X33P
X33P
X33P
X33P
X33P

frei

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

3 - 82

ELECTRICAL SYSTEM

WX210 - WX240

NOTES

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

Service manual
Section 4 Electronics
WX210 - WX240

9-91270

4-2

ELECTRONICS

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4-3

4-4

ELECTRONICS

WX210 - WX240

Table of contents

CONTROL ...................................................................................................... 7
Introduction ..................................................................................................................................... 7

ELECTRONIC CONTROL UNIT..................................................................... 8


Introduction ..................................................................................................................................... 9
ESX controller ................................................................................................................................................ 9
Central electronic system / Central Unit......................................................................................................... 9
PCS................................................................................................................................................................ 9

CAN bus (digital technique)......................................................................................................... 10


CAN bus, definition ...................................................................................................................................... 10
Electronic control diagram ........................................................................................................................... 11
CAN bus wiring ............................................................................................................................................ 12

POWER SUPPLY ......................................................................................... 14


Electrical circuit diagram CAN-bus power supply..................................................................... 14
Power supply and CAN bus in acc. with diagram P/N 8916249, sheet 40 ............................... 15
Power supply, description ............................................................................................................................ 15
Grounding .................................................................................................................................................... 15

COMPONENTS AT CAN BUS 1................................................................... 16


Central electronics A100, Central Unit (CU) ............................................................................... 16
Description ................................................................................................................................................... 16

Multi-function display C4 / A400.................................................................................................. 17


Description ................................................................................................................................................... 17

Key-board modules C5.1/A501, C5.2/A502, C5.3/A503 .............................................................. 17


PCS, Power Control System with load-limit regulator A10 ....................................................... 18
Description ................................................................................................................................................... 18

Diagnosis socket A10X4 .............................................................................................................. 19


Description ................................................................................................................................................... 19

ESX controller A7.3....................................................................................................................... 19


Description ................................................................................................................................................... 19
Technical data.............................................................................................................................................. 19

ESX power supply......................................................................................................................... 20


Pin assignment ESX controller .................................................................................................................... 21

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4-5

COMPONENTS AT CAN BUS 2................................................................... 22


Right joystick A56 for boom and bucket cylinder ..................................................................... 22
Right joystick, description ............................................................................................................................ 23

Left joystick A57 for stick cylinder and slewing mechanism ................................................... 24
Left joystick, description............................................................................................................................... 25

Joystick characteristics ............................................................................................................... 26


Left joystick .................................................................................................................................................. 26
Right joystick ................................................................................................................................................ 26
Description ................................................................................................................................................... 27

Functioning principle of joysticks and pedals........................................................................... 28


Description ................................................................................................................................................... 28

Driving pedal (master) A61 .......................................................................................................... 30


Characteristic ............................................................................................................................................... 30

Double pedal (slave) A61.1 for adjusting cylinder or hammer/shears..................................... 31


Description ................................................................................................................................................... 31

Diagnostic connector A7.3X4 ...................................................................................................... 32

ESX CODING ............................................................................................... 34


Schematic ...................................................................................................................................... 34
Description ................................................................................................................................................... 34

ESX coding .................................................................................................................................... 35

PCS POWER CONTROL SYSTEM........................................................... 36


Function chart and component layout plan ............................................................................... 36
Function listing, description.......................................................................................................................... 37

Fundamental principle of pump control ..................................................................................... 38


Description ................................................................................................................................................... 38

Regulating circuit.......................................................................................................................... 39
Speed characteristics of the engine under load........................................................................................... 39
Detection of the load status ......................................................................................................................... 39
Regulating process ...................................................................................................................................... 39

PCS performance diagram........................................................................................................... 41


PCS................................................................................................................................................. 42

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4-6

ELECTRONICS

WX210 - WX240

PCS COMPONENTS.................................................................................... 43
Load-limit regulator ...................................................................................................................... 43
Speed actuator M10 ...................................................................................................................... 44
Decription ..................................................................................................................................................... 45

Speed sensing............................................................................................................................... 46
Description ................................................................................................................................................... 46
Speed sensor (pickup) B10.1....................................................................................................................... 46

Coolant temperature sensing ...................................................................................................... 47


Description ................................................................................................................................................... 47
Temperature sensor B13.1 .......................................................................................................................... 47

Charge-air temperature sensing.................................................................................................. 48


Description ................................................................................................................................................... 48
Temperature sensor R10.3 .......................................................................................................................... 48

Hydraulic oil temperature sensing .............................................................................................. 49


Description ................................................................................................................................................... 49
Temperature sensor R14 ............................................................................................................................. 49

Proportional valve Y10 ................................................................................................................. 50


Description ................................................................................................................................................... 50

A8V with measuring point X3 for control pressure ................................................................... 51


Description ................................................................................................................................................... 51
Sectional drawing......................................................................................................................................... 51

Fan control with proportioanl valve Y131................................................................................... 52


Description ................................................................................................................................................... 52

Hammer / shears control with boom adjusting equipment (7-spool control block)................ 53
Description ................................................................................................................................................... 53

Hammer / shears equipment........................................................................................................ 54


Speed actuator .............................................................................................................................. 55

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

CONTROL

4-7

40000307-en

Introduction
The description of the machine control is divided
into 3 parts:
- Automotive electrical system
- Electronic systems with
the central electronic unit,
the electro-hydraulic pilot control and
the electronic load-limit regulation.
- Hydraulic system described according to the
power flow in the machine and the individual
functions and combined functions.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4-8

ELECTRONICS

WX210 - WX240

ELECTRONIC CONTROL UNIT

40000308-en

- ESX coding

- Introduction
- ESX controller
- Central Unit

- Electrical circuit diagram ESX coding


- PCS Power Control System

- PCS

- Basic principle of pump regulation

- CAN bus

- Control circuits
- Electrical circuit diagram PCS
- Load-limit regulator A10

- Power supply
- Electrical circuit diagram of power supply and
CAN bus
- Power supply and grounding

- Electrical circuit diagram speed adjusting motor


- Speed adjusting motor M10 with installation information
- Speed sensing

- Components of CAN bus 1

- Coolant temperature sensing

- Central electronic unit A100, Central Unit / CU

- Charge air temperature sensing

- Display C4/A400 and keyboard modules


C5.1/A501, C5.2/A502, C5.3/A503

- Hydraulic oil temperature sensing

- PCS Power Control System with load-limit regulator A10


- Diagnosis connectors A10X4 for CAN bus 1
and A7.3X4 for CAN bus 2
- ESX A7.3 electrical circuit diagram

- Proportional valve Y10


- A 8 V with pressure measuring point X3
- Fan control with proportional valve Y131
- Hammer/shears control with adjusting equipment

- Components of CAN bus 2


- ESX A7.3
- Joystick right A56 for boom and bucket cylinder
- Joystick left A57 for stick cylinder and slewing
- Joystick characteristics
- Functional principle of joysticks and pedals
- Travel pedal (master) A61
- Double pedal (slave) A61.1, option for adjusting equipment or hammer/shears
- Diagnosis connector A7.3X4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Introduction

4-9

40000462-en

The use of electronic control systems is also gaining progressive significance in mobile construction
machines. The demand for increasingly efficient
machines with greater safety and comfort and the
simultaneous pressure to optimize production
costs mean an ever-increasing demand for electronic systems to be used.

Central electronic system / Central Unit

In this context, electronic hydraulic systems are


being installed in mobile excavators to control the
entire working hydraulics and electrohydraulic
systems for engine and pump management, using
control electronics.

The engine control system gives the machine


enhanced operating comfort. It comprises a multistage power selector in conjunction with speed
steps and automatic speed reduction during working intervals.

ESX controller

PCS

The ESX controller is a freely programmable control and regulating electronic system for machines
with CAN bus. The ESX is an autonomously operating measuring, control and regulating unit for
sensor-actor management, allowing several
autonomous or interlinked tasks to be processed
in real time. The ESX has been developed specifically for use in machines that have to work
efficiently under harsh conditions and at extreme
operating temperatures of -40 to +85 C.

The Pump Control System is an electronic system


and, in conjunction with the CU, an engine control
system whose electronic control system is also
referred to as load limit regulator.

All inputs and outputs are overvoltage-protected,


short-circuit-proof and diagnosable.
Proportional valves can be directly controlled. A
sturdy die-cast aluminium housing offers both
maximum resistance to electromagnetic interference and reliable protection against mechanical
stress.

The central electronic system, in brief CU, processes the signals transmitted by the keys at the
display and by the keyboard modules. The engine
control system is implemented in conjunction with
the PCS.

The pump control system ensures that the power


intake of the working pumps is precisely balanced
with the power output of the diesel engine. Optimum use can thus be made of the available engine output.
Account is taken automatically of unfavourable
deployment conditions through adaptation of the
hydraulic output.
The driving motor and the hydraulic system are
protected by monitoring mechanisms.
The temperatures of the intake air, the coolant
and the hydraulic oil are registered by the load
limit regulator and kept within limits by the speed
regulating mechanism of the fan drive.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 10

ELECTRONICS

CAN bus (digital technique)


The CAN bus system is a communication medium
for the electronic components installed in the machine. It is a kind of data highway that connects
the ESX as an electrohydraulic servo-control and
the central electronic unit with the display/keyboard modules and with the PMS/PCS in
mobile excavators.

CAN bus, definition


CAN (Controller Area Network) technology originated in the vehicle construction sector and was
developed by Bosch. The factor underlying this
development was the increasing use of electronic
modules in automobile construction. These modules were installed at various points in the vehicle
and had to be interlinked. Direct cabling rapidly
proved to be impractical.
CAN was developed by Bosch as a serial bus with
real-time capability and high data transmission
security, meanwhile specified under ISO 11898.
Yet the bus line consists of only two cables, the
signal bearers (CAN - high and CAN - low), and
ground cables.

Was is CAN capable of ?

WX210 - WX240

The identifiers qualify not only a user address but


also the contents of a message, such a temperature, rpm or speed.
All users check with reference to the received
identifier whether the transmitted message is of
relevance to them. This means that each message can be taken over by more than one user
simultaneously. In addition, it is through the identifier that the priority of a message with respect to
bus access is determined.

Tasks
- To make the information from one control unit
serviceable for all others.
- To reduce the number and thickness of the electric cables.
- To monitor the execution of commands and thus
to make the process more reliable.
- To expand the fault-detection and diagnostic
area.

Advantages
- The overall system is more reliable. For example, it contains fewer susceptible plug connections.

As stated, the CAN bus has real-time capability,


indicating high transmission rates. The state-ofthe-art CAN bus has a maximum capacity of 1
Mbit/s.

- Wiring is less complex and thus more costeffective.

Various fault detection mechanisms enable the


CAN protocol to detect and correct transmission
faults resulting from electromagnetic radiation, for
example (transmission stop and automatic message repeat).

- Additional control elements can be readily


added.

Due to short data packets (max. 8 useful bytes


per message) time loss through data repetition
after a transmission fault is minimized.

- Simplified installation.

- The diagnostic potential of the system is improved.


- The system can be accessed to read out data
and to change parameters or performance data.

Disadvantages

How does CAN work ?

- A specific communication speed is required.

The CAN bus consists essentially of two bus cables (CAN + und CAN -). A message to be transmitted consists of an unequivocal identifier, a priority and 0 to 8 message bytes.

- Each sensor connected to the bus needs a controller.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 11

Electronic control diagram

4100726

Fig. 1

Description
The diagram shows the interlinking of the electronic and hydraulic components.
The modules responsible for the operation and
control of the electrical system of the vehicle, e.g.
display (C4), central electronic unit CU (Central
Unit A100), keyboard module (C5.1, C5.2, C5.3)
and PMS/PCS with load limit regulator (GLR A10),
and ESX (A7.3) are connected to CAN bus 1.
CAN bus 1 has the diagnostic sockets.

The electronic modules of the electrohydraulic


servo control, e.g. joystick on right (A56) and left
(A57), as well as the driving pedal (A61) and the
double pedal (A61.1) are connected with the ESX
via CAN bus 2.
The two BUS systems are interlinked via the ESX.
The ESX controls the pump control, the control
valve adjustment, and the slewing pump control
systems.
In addition, the ESX issues current values via
CAN bus 1 at the load limit regulator to the hammer/shears control.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 12

ELECTRONICS

WX210 - WX240

CAN bus wiring

4100730

Fig. 2

Description

Wiring

The microcontroller network is shown in the diagram.

The two bus lines are twisted 30 times per meter


against each other (twisted pair).

Each of the electronic components is equipped


with its own microcontroller.

Reason: Disturbing influences would act on both


lines.

Two CAN buses CAN1 and CAN2 are used in the


mobile excavators. This ensures that the modules
interlinked at CAN bus 1, e.g. central electronic
unit/CU, display C4, keyboard modules C51, C52,
C53, and the PCS can operate independently of
the modules of the electrohydraulic servo control
which are interlinked at CAN bus 2.
Both CAN buses are equipped at their ends with
terminating resistors.
The terminating resistors for CAN1 are housed on
the one hand in the display C4 and on the other
hand in the ESX.
The terminating resistors for CAN2 are located in
the ESX and in the left joystick.

Fig. 3

The twisting of the two lines is shown as above in


the circuit diagram.

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WX210 - WX240

ELECTRONICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 13

4 - 14

ELECTRONICS

WX210 - WX240

POWER SUPPLY

40000463-en

K10.1

K100

K10.1

K-ESX

Electrical circuit diagram CAN-bus power supply

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Power supply and CAN bus in acc. with


diagram P/N 8916249, sheet 40

4 - 15

Grounding

Power supply, description


The battery voltage +30 is available at the ignition
starter switch S1 and the two diagnosis sockets.
After switching on of the ignition with S1 and as
long as the key is held in this position, battery voltage +30 is connected to terminal +15 and:
- the central electronic unit A100, also called Central Unit (CU), is supplied with power;
- power relais K10.1 is energized; its contact energizes relay K100 whereby the CU/A100 is supplied with power and starts booting;
- the ESX is supplied via the 30A fuse. The ESX is
moreover supplied with power via the 2A fuse;

Fig. 2

- relay K-ESX is energized.


After booting of the CU, voltage Ub (15b) is available at two contacts.
- via X3A: 8 the modules display C4, keyboard
modules C5.1, C5.2, C5.3, both joysticks and the
travel pedal are supplied. The travel pedal as a
master module supplies power to the double
pedal (slave).
- via X7:5-6 power relay K10.1 is energized for
self-maintaining contact (after releasing of the
ignition key); moreover load-limit regulator A10 is
supplied with power.
Fig. 3

All modules are connected to the central grounding


point X31P on the platform plate.
This grounding point penetrates through the platform plate.
Grounding point X31P of the elastically supported
platform plate is connected with an earthing strap
to the superstructure frame.
The ESX is grounded via its fastening screws.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 16

ELECTRONICS

WX210 - WX240

COMPONENTS AT CAN BUS 1

40000464-en

Central electronics A100, Central Unit (CU)

Fig. 1

Description

Switching on the ignition

The central electronic unit performs the following


functions:

The central electronic unit is switched on with


ignition switch S1; an LED on the circuit board
must start flashing.The CU boots and and supplies the connected modules via 15b.

- Master function for switching components on


and off
- System status monitoring, buzzer control
- Control of the vehicle electrics
- Control of speed actuator motor
- Gearshift, creep speed, floating axle
- Travel speed sensing with failure detection of
double sensor, calibration
- Immobilizer

Switching on the hazard warning system


When the hazard warning system is switched on
(ignition off), the central electronic unit is also
switched on, however without booting thereafter.
The LED on the ciruit board remains off. The
rhythmic hazard warning flashing signal is generated by the central electronic unit. Computation of
data is performed by a plug-in module on the circuit board of the central electronic unit.
The micro-controller MC on the module is programmable/flash-loadable via the diagnosis
socket A10X4 for can bus 1.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Multi-function display C4 / A400

4 - 17

Key-board modules C5.1/A501,


C5.2/A502, C5.3/A503

4100732

Fig. 2

Description
The multi-function display is equipped with:
- a display screen with 128x64 pixels
- three keys Up/Down/Set
- seven pilot lamps
- two warning lamps for fault messages
The internal micro-controller is programmable via
diagnosis socket A10X4 for CAN BUS 1.
It is programmable with a software for the program and another software for texts, graphics and
languages.

4100733

Fig. 3

The three key-board modules are eqipped with


four keys each. A key can be depressed repeatedly for two or more switching states. A press on
a key is acknowledged by the tactile touch keys.
Some of the keys have LEDs above them.
- Module C5.1 has 2 LEDs
- Module C5.2 has 7 LEDs
- Module C5.3 has 4 LEDs
After depressing a key with an LED, the LED does
not light up immediately but with a delay.
The LEDs have acknowledging function. They
light up only after the switching process of a solenoid valve has been detected from the corresponding flow of current.
Each key-board module has its own microcontroller with the same software. The modules
are not programmable.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 18

ELECTRONICS

WX210 - WX240

PCS, Power Control System with load-limit regulator A10

Fig. 4

Description
The functions of the PCS are:
- Engine control with
- 7 speed stages (7 power stages), auto idle,
low idle
- engine warm-up phase
- Pump Control System with
- load-limit regulation in power stages 7 and 6
and with road travel
- 7 power stages and additional power amplification for road travel
- engine speed detection
- temperature detection
- fan control

The PCS is an electronic pump control system


and an engine control system.
The load-limit regulator in the pump control system ensures that the power absorbed by the working pumps corresponds to the power supplied by
the diesel engine. The available engine power can
thus be used in the best possible way.
Unfavourable conditions of use are taken care of
automatically by adapting the hydraulic power.
The drive engine and the hydraulic system are
protected by monitoring systems.
The temperatures of charge air, coolant and the
hydraulic oil are detected by the load-limit regulator and kept within predefined limits by controlling
the speed of the fan drive.
The load-limit regulator is programmed with a
special adapter and special software in the factory
of the manufacturer.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 19

Diagnosis socket A10X4

ESX controller A7.3

Fig. 5

Fig. 6

Description

Description

The picture shows the fuse box on the right behind


the driver's seat and the diagnosis sockets.

To permit data exchange with other electronic systems, the device is provided with two CAN bus
interfaces in acc. with CAN specification 2.0 B and
an RS232-interface to permit connecting several
micro-controllers via the CAN bus.

The upper socket is the diagnosis socket A10X4


for CAN bus 1 and all electronic components connected to it.
A10X4 can be used for connection of a service tool
(in preparation) by means of an adapter.

Technical data

The central electronic unit (A100) and the multifunction display (C4) can be programmed flashloaded with the service tool.

Interfaces:

The lower diagnosis socket is the socket A7.3X4


for CAN bus 2. This socket is used to program the
electro-hydraulic control in the factory of the manufacturer.

- 1x RS232

Type: C167 CS
- 2x CAN-Bus
In / Out:
- 17x PWM-outputs with current control
- 7x PWM-outputs
- 8x analogue inputs (0..8,5V or 0..20mA)
- 16x digital inputs
68 PIN connector

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 20

ELECTRONICS

WX210 - WX240

ESX power supply

40000519-en

Fig. 31

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 21

Pin assignment ESX controller

40000583-en

Fig. 7
Fig. 8
Pin

Function

Pin

Function

Ground, analog

35

Digital speed input 3

Digital/PWM output 10, (2,5 A)

36

Digital speed input 5

Digital/PWM output 12, (2,5 A)

37

Digital speed input 7

Serial interface, RxD

38

Digital speed input 9

Serial interface, TxD

39

Digital speed input 11

Analog input 1

40

Digital speed input 13

Analog input 3

41

Digital speed input 15

Analog input 5

42

Baby-Board, slot 1/1

Analog input 7
Baby-Board, slot 2/6
Baby-Board, slot 2/2
Digital speed input 2
Digital speed input 4
Digital speed input 6
Digital speed input 8
Digital speed input 10
Digital speed input 12
Digital speed input 14
Digital speed input 16
Baby-Board, slot 1/2
Baby-Board, slot 1/4
Baby-Board, slot 1/6
8,5 V out
Digital/PWM output 9, (2,5 A)
Digital/PWM output 11, (2,5 A)
st
1 CAN-Bus, dominant lower, Wst
1 CAN-Bus, dominant higher, W+
D+ input
Analog input 2
Analog input 4
Analog input 6
Analog input 8
nd
2 CAN-Bus, dominant lower, WDigital speed input 1

43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68

Baby-Board, slot 1/3


Baby-Board, slot 1/5
Baby-Board, slot 2/1
Digital/PWM output 1, (4 A with current measuring)
Digital/PWM output 2, (4 A with current measuring)
Digital/PWM output 3, (4 A with current measuring)
Digital/PWM output 4, (4 A with current measuring)
Baby-Board, slot 2/3
Baby-Board, slot 2/4
Baby-Board, slot 2/5
nd
2 CAN-Bus, dominant higher, W+
Power supply 12 V (24 V), UE
Electrical ground, digital
Power supply 12 V (24 V), UB
Power supply 12 V (24 V), UB
Power supply 12 V (24 V), UB
Power supply 12 V (24 V), UB
Power supply 12 V (24 V), UB
Digital/PWM output 6, (4 A)
Digital/PWM output 7, (4 A)
Digital/PWM output 8, (4 A)
Digital/PWM output 5, (4 A with current measuring)
Ground for Babyboard 1
Ground for Babyboard 1
Ground for Babyboard 2
Ground for Babyboard 2

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

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4 - 22

ELECTRONICS

WX210 - WX240

COMPONENTS AT CAN BUS 2

40000465-en

Right joystick A56 for boom and bucket cylinder

Fig. 1

Pushbuttons F1 - F5 are explained in the table


below; see also Owners Manual.
Legend
F1

Driving direction forwards

F2

Driving direction reverse

F3

Turn grab clockwise

F4

Horn

Legend

F5

Driving direction neutral

PIN1

CAN2 high

PIN2

CAN2 low

PIN3

Voltage + 15b (Ub)

PIN4

Ground (GND)

Fig. 2

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WX210 - WX240

ELECTRONICS

4 - 23

Right joystick, description


The joystick is shown without its bellows.
The wiring comprises the two bus lines from the
ESX plus the voltage and ground supply.
The four lines are looped through the joystick and
also connect the left joystick A57.

Fig. 3

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4 - 24

ELECTRONICS

WX210 - WX240

Left joystick A57 for stick cylinder and slewing mechanism

Fig. 4

Pushbuttons F1 - F5 are explained in the table


below; see also Owners Manual.
Legend
F1

Power boost

F2

Stick / stabilizer switchover

F3

Turn grab counter clockwise

Legend

F4

Hydraulic hammer

PIN1

CAN2 high

F5

Levelling mode of operation

PIN2

CAN2 low

PIN3

Voltage + 15b (Ub)

PIN4

Ground (GND)

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

Left joystick, description

ELECTRONICS

4 - 25

The joystick is shown without its bellows.


The wiring consists of bus lines CAN high and
CAN low and of the voltage supply and ground.
The four wires are part of a harness plugged into
the right joystick

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4 - 26

ELECTRONICS

WX210 - WX240

Joystick characteristics

Fig. 6

Left joystick

Right joystick

Fig. 7

Fig. 8

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 27

Description
The two diagrams show the characteristics for the
left and right joystick.

The characteristics of the X-axis show the transverse movement of the joystick handle.

The characteristics of the Y-axis show the forward


and reverse movement of the joystick handle and
the change in digit value in relation to the angular
deflection.

Digit output starts at a joystick handle deflection of


>0.7.
In the X- and in the Y-axis, 512 digits are put out
in the event of full deflection from the zero position.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 28

ELECTRONICS

WX210 - WX240

Functioning principle of joysticks and pedals

Fig. 9

Description
The joysticks are manually controlled pulse generators that permit the handle to be swivelled in
any direction. The swivelling / pedal movements
are picked up by sensors and put out via the interfaces as digital signals.

Joystick/pedal position detection and


evaluation
The position of the movement axes is detected
contact-free by Hall-effect sensors. Two Halleffect sensors per movement axis are used to
ensure that the joystick operates correctly. The
plausibility control of the signals is based on redundant signal evaluation, i.e. the internal microcontroller computes from the measured value of a
Hall-effect sensor the probable value of the other
sensor and then compares the computed with the
measured value. If the difference between the two
values exceeds a defined tolerance window, a
troubleshooting routine comes into force.

During this process, all joystick and pedal functions are deactivated and a re-start of the unit is
initiated.
The position of the joystick handle, i.e. the angular
deflection into one or more directions, is registered in the same way for all joysticks. Four Halleffect sensors (two for X-direction and two for Ydirection) are mounted on a fixed p.c. board in the
joystick housing. An annular magnet is attached to
the articulated cardan joint at the top of which the
joystick handle is located. On deflection of the
joystick handle into one direction, the distance of
the annular magnet from the sensors located in
movement direction is reduced or increased. The
resulting changes in the output voltages of the
Hall-effect sensors are converted by the controller
into a digital value and can thus be further processed.
The definitive output signal results as a digital
value from conversion, amplification and calibration.

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WX210 - WX240

ELECTRONICS

4 - 29

Fig. 10

Temperature compensation
Temperature compensation is used to reduce the
unavoidable influencing of the signals in their digital/analog conversion through changes in ambient
temperature. This compensation is executed subsequent to the A/D conversion in the microcontroller by a software program, with the actual ambient
temperature being ascertained by an integrated
temperature sensor and used for computation
purposes. This procedure ensures high stability of
the output signals, irrespective of fluctuations in
ambient temperature, in a broad temperature
range from -40C to +85C.

Power supply
The power supply of the controller is designed for
an input voltage ranging from 8V to 30V DC.

The 5V supply is monitored by a reset controller. If


the supply voltage falls below 4.5V, the reset controller generates a reset signal that resets the
supervisory controller (SC) directly. With the resetting of the SC, the main controller (MC) is also
automatically reset; it is kept in this state until the
SC goes through its initialization procedure again.
Only then is the MC released from the reset status
by the SC.

Reverse voltage protection


Joystick/pedals have reverse voltage protection at
the inputs. In addition, the inputs of the supply
voltage and the outputs of the circuit are protected
against positive and negative voltage peaks by
600W suppressor diodes.

It supplies the electronic system with a controlled


voltage of 5V.

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4 - 30

ELECTRONICS

WX210 - WX240

Driving pedal (master) A61

Fig. 11

CAN plug assignment:


PIN1

CAN2 high

PIN2

CAN2 low

PIN3

Voltage + 15b (Ub)

PIN4

Ground (GND)

Characteristic

Slave plug assignment:


PIN 1

HAL x. 1A

PIN 2

HAL x. 1B

PIN 3

+24 V

PIN 4

Ground (GND)

PIN 5

HAL x. 2A

PIN 6

HAL x. 2B

PIN 7

Normal position x

PIN 8

free

Fig. 12

The diagram shows the characteristic of the driving pedal.


On activation of the pedal by >0.7 out of zero
position, digit output is started. 512 digits are put
out on max. activation.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 31

Double pedal (slave) A61.1 for adjusting cylinder or hammer/shears

Fig. 13

Description

Slave plug assignment:


PIN 1

HAL x. 1A

PIN 2

HAL x. 1B

PIN 3

+24 V

PIN 4

Ground (GND)

PIN 5

HAL x. 2A

PIN 6

HAL x. 2B

PIN 7

Normal position x

PIN 8

free

Fig. 14

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 32

ELECTRONICS

Diagnostic connector A7.3X4

WX210 - WX240

The photo shows the fuse box on the right behind


the operators seat and the diagnostic connectors.
The lower connector is diagnostic connector
A7.3X4 for CAN bus 2. Using this connector, the
ESX controller for the electrohydraulic control with
the relevant electronic components is programmed
at the factory.
The upper connector is diagnostic connector
A10X4 for CAN bus 1 and all electronic components connected to it.
A service tool (in preparation) can be connected at
A10X4 by means of an adapter.

Fig. 15

The central electronic unit (A100) and the multifunction display (C4) are programmable / flashable
with the service tool.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 33

4 - 34

ELECTRONICS

WX210 - WX240

ESX CODING
Schematic

40000466-en

Description
Coding of the ESX controller is performed at the
factory of the manufacturer before the machines
are delivered.
The cable harness to the ESX comprises connectors XC1, XC2 and XC3.
Connector XC1 permits changing the SAE control
to other control systems by means of different coding jumpers.
Connector XC2 is equipped with coding jumpers
for boom-adjusting equipment or for mono-block
boom equipment.

Fig. 1

If the boom (adjustable boom versus mono-block


boom or vice versa) is replaced, the coding jumpers must also be replaced.
Connector XC3 is provided with the standard coding jumpers.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

ESX coding

4 - 35

40000474-en

Fig. 33

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 36

ELECTRONICS

WX210 - WX240

PCS POWER CONTROL SYSTEM

40000532-en

Function chart and component layout plan

4100746

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 37

Function listing, description


GLR

Load limit regulator A10: contains the machine-specific parameters, controls with the CU
the speed-changer motor (speed actuator) M10, records the engine speed and specifies
setpoint speeds as reference speeds for working/travelling, registers the temperatures,
controls the fan speed, influences via proportional valve Y10 the output of the main
pumps A 8 V.

C4

Display, including setting of various performance parameters for hammers and other
attachments apart from shears.

C5.1

Keyboard module for 7-stage speed adjustment, Auto Idle and Low Idle

C5.2

Keyboard module including for travel on the highway

C5.3
CU

Central electronic unit, including for the control of the speed actuator motor M10

M10

Speed actuator motor

B10.1

Diesel engine speed sensor, pick-up

B13.1

Coolant temperature sensor, diesel engine

R10.3

Charge air temperature sensor, diesel engine

R14

Hydraulic oil temperature sensor, hydraulic system

Y10

Proportional valve for output adjustment of main pumps A8V

A8V, X3

Main pumps P1 and P2 with connection X3 and pressure measuring point

Y131

Proportional valve for fan speed control

ESX

Controller for electrohydraulic control, including output of current ratings via CAN1 to the
load limit regulator for hammer/shears co

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 38

ELECTRONICS

WX210 - WX240

Fundamental principle of pump control

Fig. 2

Legende
1

Diesel engine

Main pumps

Slewing pump

Pilot-control pump

Slewing oil motor

Proportional valve

Servo-control pressure limitation

Load limit regulator

Actual value

Setpoint value

Control current

Description
The task of the electronic load limit regulator is to
adapt the hydraulic output of the pumps to the
available engine output.

The principle applied here is that of scales, with


the engine output on one side and the hydraulic
output of all pumps on the other.
The sum total of the installed hydraulic output is
clearly in excess of the engine output. The set
output of each main pump corresponds approximately to the max. engine output; in addition there
are the outputs of the slewing pump and the gear
pumps.
To provide a balance between engine output and
hydraulic output, the load limit regulator influences
only the output of the main pumps. The outputs of
slewing pump and gear pumps are not influenced.
During work with the machine, intermittent functions such as slewing or brief steering take up
engine output. The difference in output from the
serviceable engine output is provided by the load
limit regulators of the two main pumps. The load
limit regulator continuously compares the actual
values with the setpoint values. In the event of an
imbalance, the load limit regulator intervenes in
the power input of the main pumps via the proportional valve.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Regulating circuit
Speed characteristics of the engine under
load
The diagram shows the principle of a torque characteristic:

4 - 39

Detection of the load status


The load limit regulator detects the activation of
working or driving functions from the ESX controller.
The ESX opens virtual pressure switches, comparable with pressure switches that open during
working functions or driving operations.
The message Pressure switch open brings the
ESX into contact with the CAN bus. When the
load limit regulator receives this message, it
stores the momentary engine speed. With the Pdegree taken into account, the load limit regulator
stipulates the setpoint speed as the reference
speed.
Proportional valve characteristic:

Fig. 3

The torque characteristic illustrates the connection


between speed suppression and torque of the
diesel engine.
At basic load 1 the high idling speed is set at point
A.
If the diesel engine is loaded by the pumps, the
result is speed suppression with a simultaneous
increase in torque along the limit characteristic AB
up to rated speed at point B.

Fig. 4

If the pump output exceeds the engine output, the


speed is further suppressed towards point C.

Regulating process

This speed suppression causes the load limit


regulator to reduce the main pump output until the
engine can operate again with rated speed at
point B.

The load limit regulator regulates the power input


of the main pumps, so that the setpoint speed is
maintained or the load does not fall short of the
load limit.
The control current of the load limit regulator is
converted by the proportional valve into control
pressure.
Both pump regulators are thus loaded. The pumps
are adjusted towards max. power input until a
balance has been established between hydraulic
input and engine output. This state is referred to
as the diesel engine load limit.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 40

ELECTRONICS

WX210 - WX240

PCS in neutral

PCS when working

If no hydraulic function is activated, the power


input of the main pumps is minimized by a high
control current of the load limit regulator to the
proportional valve Y10.

When working with the working hydraulics, the


speed signal of the diesel engine is evaluated,
and the loading state of the engine is thus recognized, at each power stage. This means that any
change in diesel engine speed to above or below
the reference speed entails a control current
adapted to the output of the diesel engine.

The resulting control pressure is ca. 40 bars.


The seven possible power stages would be noticeable only as engine speed stages.
During driving, only pump 1 is loaded. The mechanical power setting of pump 1 complies closely
with the installed diesel engine output.

PCS when driving on the public highway


Power stages 6 to 1 are given the engine speed
and pump output of the next higher power stage
Power stage 7 is given a 5% higher pump output,
which corresponds to the mechanical power setting of a pump.

PCS when driving on terrain


Power stages 7 to 1 are available for the driving
function.
If further working functions are activated while the
machine is being driven, the load limit of the diesel engine is reached immediately, with the outcome that the control pressure pSt rises and the
output of the main pumps is thus reduced. This
power reduction continues until the power balance
between the engine output and the hydraulic input
is restored.

This control current is the output signal of the load


limit regulator. The proportional valve Y10 converts this control current proportionately into control pressure pSt, causing the power regulator of
the main pumps at connection X3 to be activated.
If the full hydraulic output is not utilized, the diesel
engine speed rises to above the reference speed
on account of the lower total load. The result is
that the load limit regulator counter-controls and
increases the power intake of the main pumps by
putting out a lower control current to the proportional valve in order to load the main pumps with a
lower control pressure pSt.
The result is that the regulating pressure of the
main pumps, which is within the normal range in
this situation, is raised and the power input is increased by increasing the volumetric flow.
If the main pumps are in the pressure range below
the start of regulation, the load limit regulator signal cannot influence the power input of the main
pumps.
The electronic load limit regulation attained in this
way in conjunction with individually output-controlled main pumps ensures optimum utilization of
the available diesel engine output.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 41

PCS performance diagram


Prinzipielles Leistungsdiagramm PCS

Hochdruck in bar

100% Motorleistung
fr 1 Pumpe

350

95% Motorleistung
fr 1 Pumpe

100% Motorleistung
fr 2 Pumpen

PCS-Druck in bar

400

10

300
95% Motorleistung
fr 2 Pumpen

85% Motorleistung
fr 2 Pumpen

250

15

80% Motorleistung
fr 2 Pumpen
20

200
75% Motorleistung
fr 2 Pumpen
70% Motorleistung
fr 2 Pumpen

150

25

65% Motorleistung
fr 2 Pumpen
100

30

50

35

40

0
0

20

40

60

80

100

120

140

160

180

Volumenstrom in l/min

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 42

ELECTRONICS

WX210 - WX240

PCS

40000499-en

Fig. 8

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 43

PCS COMPONENTS
Load-limit regulator

Fig. 1

40000471-en

Legend
1

Power supply

PWM1 output, proportional valve Y10

PWM2 output, proportional valve


Y207b

PWM3 output, proportional valve


Y207a

Input from B13.1, coolant temperature

Input from R10.3, charge-air temperature

Input from R14, hydraulic oil temperature

8
9
10
11
12
13
14
15
16
Fig. 2

17
18

Output, fan control Y131

19
20
21

CAN1 High to CU A100

22

CAN1 Low to CU A100

23
24

Input from sensor B10.1

25

Ground, cable cross-section 2.5 mm

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 44

ELECTRONICS

WX210 - WX240

Speed actuator M10

Fig. 3

Pin assignment:
PIN 1

motor

PIN 2

potentiometer

PIN 3

potentiometer/back check

PIN 4

potentiometer

PIN 5

motor

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

4 - 45

Decription
The speed actuator converts the speed stages
preselected at key-board module C5.1 into diesel
engine speeds.
The PWM signals from the CU set the actuator
lever to different positions. This lever actuates the
injection pump lever via a linkage.
See also circuit diagram 8900298 sheet 10, speed
actuator, at the end of this section.

Fig. 5

Fitting instructions:

Installation of speed actuator M10 with linkage:


- The dimensions specified must be observed
during fitting
- Carry out calibration after fitting.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 46

ELECTRONICS

Speed sensing

WX210 - WX240

Speed sensor (pickup) B10.1

Speed sensor B10.1:

Fig. 6

Description
When the diesel engine is running, the load-limit
regulator A10 receives permanently a frequency
signal from the speed sensor (inductive pickup)
B10.1.
The inductive pickup is screwed into the fly-wheel
housing of the engine opposite the toothing.
The frequency signal is derived from the alternation between tooth and spacewidth in the induction field of the sensor.
The speed signal is used by the load-limit regulator to determine the load condition of the diesel
engine.

Fig. 7

FITTING INSTRUCTION
The sensor must be screwed completely down
into the fly-wheel with the connector unplugged.
The sensor must then be turned back by turn
and secured with the hex locknut size 24.
Technical characteristics:
Thread

16 UNF

Coil resistance at 20C = 450 +/-20

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Coolant temperature sensing

Temperature sensor B13.1

Fig. 8

Description
For coolant temperature monitoring, temperature
sensor B13.1 is screwed into the cylinder head of
the engine.
The sensor is an NTC resistor reducing its electrical resistance with increasing temperature.
FITTING INSTRUCTION:
Tightening torque 20 to 30 Nm
Technical characteristics:
Thread

x 14 PTF

Table: Resistance = f (temperature)


t (C)

Fig. 9

Resistance ()

5466 5896

10

3542 3792

20

2351 2500

25

1941 2057

30

1615 1707

40

1118 1175

50

798 834

60

573 596

70

421 435

80

313 323

90

237 243

100

182 186

110

140 144

120

109 113

PIN A Grid heater controller


PIN B Load-limit regulator
PIN C Ground

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 47

4 - 48

ELECTRONICS

Charge-air temperature sensing

WX210 - WX240

Temperature sensor R10.3

Fig. 10

Description
Temperature sensor R10.3 senses the charge-air
temperature at the radiator outlet or at the manifold inlet.
The sensor is an NTC resistor reducing its electrical resistance with rising temperature.
FITTING INSTRUCTION:
Tightening torque

20 Nm

Technical characteristics:
Thread

Fig. 11

M14x1.5

Table: Resistance = f (temperature)


t (C)

Resistance

PIN1

Load-limit regulator

2700 3300

PIN2

Ground

10

1600 2000

20

1000 1280

25

890 970

30

650 800

40

430 530

50

290 350

60

200 240

70

140 170

80

100 120

90

77

90

100

58

67

110

44

50

120

35

39

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Hydraulic oil temperature sensing

4 - 49

Temperature sensor R14

Fig. 12

Description
To determine the hydraulic oil temperature, temperature sensor R14 is provided.
The sensor is installed at the hydraulic reservoir
besides the suction line for the main pumps.
The sensor is an NTC resistor reducing its electrical resistance with rising temperature.
FITTING INSTRUCTION:
Tightening torque

20 Nm
Fig. 13

Technical characteristics:
Thread

M14x1.5

Table: Resistance = f (temperature)


t (C)

Resistance

20

1038 1268

30

701 839

40

450 540

50

331 389

60

214 250

70

166 194

80

116 134

90

80

92

100

60

68

PIN1

Load-limit regulator

PIN2

Ground

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 50

ELECTRONICS

Proportional valve Y10

WX210 - WX240

When the emergency operation


function is activated, temperature
monitoring is not operational.

Technical characteristics, electrical:


- PWM frequency: 150 Hz
- Coil resistance at 20C: 18 0,2
- Max. coil current: 850 mA
- Characteristics:
100 mA 0 bar (+ 0.5 tolerance)
800 mA 40.5 bar (+ 2.0/ -0.5 tolerance)
Fig. 14

Characteristic curve of proportional valve Y10,


control pressure as a function of control current:

Description
The proportional valve converts the control current
transmitted by load-limit regulator A10 into control
pressure.
The control pressure is admitted via port X3 to
both pump regulators of the main pumps A 8 V.
Proportional valve Y10 is installed in the pilot control unit where the pilot pressure is available at the
control piston of the proportional valve.

Emergency operation
The proportional valve is equipped with an emergency operation device.
In the event of a PCS fault and an resulting engine speed reduction, the absorbed power of the
main pumps A 8 V can be reduced to such an
extent that the diesel engine is no longer significantly throttled during the work.
Withdraw the connector from the proportional
valve.
Turn hex-screw in by abt. 2 turns after loosening
the locknut.
Let the engine run at maximum speed and load by
moving the stick cylinder against block and by
maintaining it there with an additional slewing
motion of the superstructure of more than turn.

Fig. 15

Observe the engine speed during the process:


If the engine is still throttled, turn hex-screw further down.
If the engine maintains its speed under load and if
the machine moves only slowly, the hex -screw
has been turned into far.
The emergency operation is properly adjusted if
the machine can be used for working without considerable engine throttling.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

A8V with measuring point X3 for


control pressure

4 - 51

Sectional drawing

Description
The measuring point can be used to measure the
control pressure from the proportional valve outlet.
The control pressures to be expected depend on
the type of machine and the selected power
stage.
The pressure range is between 0 and 45 bars.
Measuring point X3

X3

Fig. 17
Fig. 16

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 52

ELECTRONICS

WX210 - WX240

Fan control with proportioanl valve


Y131
Description
The fan motor is equipped with proportional valve
Y131. This valve permits the temperature-dependent and stepless change of the fan speed.
The temperatures affecting the fan speed are the
temperatures of the coolant, the diesel engine
charge air and the hydraulic oil in the system .
These three temperatures are transmitted to the
load-limit regulator and used for fan speed control.
Each of these temperatures can induce changes
of the fan speed.
At lower temperatures, the proportional valve receives a higher control current from the load-limit
regulator and vice versa. A high control current
results in a low fan speed and vice versa.
For pressure protection, the proportional valve is
equipped with an adjustable pressure-limiting valve.
When the connector is unplugged,
the fan runs at maximum speed. A
pressure gauge connected to the
measuring point will then indicate
the opening pressure of the integrated pressure-limiting valve.

Fig. 19

FITTING INSTRUCTION:
The pressure settings are machine-dependent.

Tightening torque

50 Nm

Technical characteristics:
Rated voltage

24 V

Coil resistance at 20C: 25

Fig. 18

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Hammer / shears control with boom


adjusting equipment (7-spool control
block)

4 - 53

Description
Machines with boom adjusting equipment and additional hammer / shears attachment are equipped
with a 6-spool block and an auxiliary control block.
The control spool of the auxiliary block is adjusted
by proportional valves Y207a and Y207b.
These proportional valves receive their control
current from load-limit regulator A10.
The control current is determined by the ESX depending on load conditions and transmitted over
the CAN bus.

Fig. 20

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 54

ELECTRONICS

WX210 - WX240

Hammer / shears equipment

40000448-en

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

ELECTRONICS

Speed actuator

4 - 55

40000501-en

Fig. 10

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

4 - 56

ELECTRONICS

WX210 - WX240

NOTES

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

Service manual
Section 5 Hydraulics
WX210 - WX240

9-91270

5-2

HYDRAULICS

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5-3

5-4

HYDRAULICS

WX210 - WX240

Table of contents

CONTROL .................................................................................................... 12
Introduction ................................................................................................................................... 12

HYDRAULIC SYSTEM ................................................................................. 13


Overview ........................................................................................................................................ 13
Working, slewing and pilot-control circuits in the superstructure .......................................... 14
Working, travel and pilot-control circuits in the undercarriage ............................................... 16
Hydraulic circuit diagram superstructure .................................................................................. 18
Hydraulic circuit diagram WX210 with monoblock boom equipment........................................................... 19
Hydraulic circuit diagram WX210 with boom adjusting equipment.............................................................. 20
Hydraulic circuit diagram WX240 with monoblock boom equipment........................................................... 21
Hydraulic circuit diagram WX240 with boom adjusting equipment.............................................................. 22

Hydraulic circuit diagram undercarriage, Part number 4530235.............................................. 24


Undercarriage with 25 (30) km/h axle, sheet 1 of 7 ..................................................................................... 25
Undercarriage with 25 km/h axle, sheet 2 of 7 ............................................................................................ 26
Undercarriage with A2 stabilization with individual control, sheet 3 of 7 ..................................................... 27
Undercarriage levelling blade A2 stabilization, sheet 4 of 7 ........................................................................ 28
Undercarriage A4 stabilization, sheet 5 of 7 ................................................................................................ 29
Undercarriage levelling blade A2 stabilization individual control, sheet 6 of 7 ............................................ 30
Undercarriage A4 stabilization individual control, sheet 7 of 7 .................................................................... 31

DRIVE UNIT.................................................................................................. 32
Drive unit, schematic diagram..................................................................................................... 32
Elements ...................................................................................................................................................... 33

Multi-circuit pump unit (No. 2) ..................................................................................................... 34


Multi-circuit pump unit, description............................................................................................................... 35

Variable displacement twin pump A8VO (No. 3) ........................................................................ 36


Drive unit, variable displacement twin pump output regulator (No. 3) ................................. 38
Drive unit, variable displacement twin pump - output regulator (No. 3)....................................................... 38
Output regulation by load-sensing pressure ................................................................................................ 39
Output regulation by pump high pressure.................................................................................................... 41
Output regulation by load-limit control ......................................................................................................... 43

Pilot-control pump (No. 3)............................................................................................................ 45


Description ................................................................................................................................................... 45

Drive unit, double gear pump (No. 230) ...................................................................................... 46


Description ................................................................................................................................................... 46

Drive unit, Hydraulic reservoir with attachments (Nos. 20-24) ................................................. 47


Description ................................................................................................................................................... 47

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5-5

CONTROL BLOCK....................................................................................... 48
Control block, rear view ............................................................................................................... 48
Control block, front view.............................................................................................................. 49
Control block, bottom view.......................................................................................................... 50
Control block for monoblock boom equipment with hammer / shears ................................... 52
Description ................................................................................................................................................... 53

Control block for boom adjusting equipment with hammer / shears ...................................... 54
Description ................................................................................................................................................... 55

Control block valves..................................................................................................................... 56


Primary pressure-limiting valves with pressure sequence stage (1) ........................................................... 56

Control block valves..................................................................................................................... 57


Tank channel preloading valves ............................................................................................................... 57
Secondary pressure-limiting valves with replenishing stage (SV) ............................................................... 58
Proportional valves for control spool adjustment ........................................................................................ 59
Pressure sensors ......................................................................................................................................... 60

PILOT-CONTROL SYSTEM ......................................................................... 62


Pilot-control system, description ................................................................................................ 63
Pilot-control circuit in neutral position .......................................................................................................... 63

Pilot control unit (nos. 60, 61, 63 and 64) ................................................................................... 64


Pilot control unit, schematic diagram ........................................................................................................... 65
Pilot control unit, description ........................................................................................................................ 65

Solenoid valves and their functions ........................................................................................... 66


Proportional valve Y10 of the load-limit regulator ........................................................................................ 66
Solenoids Y35 and Y113 ............................................................................................................................. 68
Solenoid valve Y35 for the superstructure holding brake in the slewing gearbox ....................................... 68
Solenoid valve Y113 for pilot pressure activation and deactivation.............................................................. 68
Solenoid valve Y290 for pilot-control activation and deactivation................................................................ 69
Solenoid valve Y63 for POWER BOOST and power assist functions ......................................................... 70
Solenoid valve unit Y241 and Y242 for pump control.................................................................................. 72

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5-6

HYDRAULICS

WX210 - WX240

TRAVEL CIRCUIT OF 20 KM/H VERSION .................................................. 74


Travel circuit 20 km/h, schematic diagram................................................................................. 74
Description .................................................................................................................................... 75
Neutral position ............................................................................................................................................ 75
Before travelling ........................................................................................................................................... 75
Start of the travel function ............................................................................................................................ 75
Forward travel .............................................................................................................................................. 75
Reverse travel .............................................................................................................................................. 75

Pressure compensator for travel circuit..................................................................................... 76


Function ....................................................................................................................................................... 76
Operation ..................................................................................................................................................... 76
Travel forward or backward ......................................................................................................................... 77

Travel control spool...................................................................................................................... 78


Hydraulic and electric rotor (Nos. 75 and 76)............................................................................. 79
Description ................................................................................................................................................... 79

Travel drive (Nos. 100, 101 and 102) ........................................................................................... 80


Description ................................................................................................................................................... 80

Travel oil motor type A 6 VM (20 km/h) (No. 102)....................................................................... 81


Travel oil motor, regulator (No. 102) ............................................................................................................ 82

Travel oil motor, travel brake valve (No. 102)............................................................................. 84


Description ................................................................................................................................................... 84

Undercarriage control block (Nos. 104, 105 and 106) ............................................................... 86


Description ................................................................................................................................................... 87

Steered floating axle (No. 110)..................................................................................................... 88


Description ................................................................................................................................................... 88

Floating-axle cylinder (No. 111)................................................................................................... 89


Description ................................................................................................................................................... 89

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5-7

TRAVEL CIRCUIT OF 25 AND 30 KM/H VERSIONS .................................. 90


Travel circuit 25 and 30 km/h, schematic diagram .................................................................... 90
Description .................................................................................................................................... 91
Neutral position ............................................................................................................................................ 91
Prior to travelling .......................................................................................................................................... 91
Start of the travel function ............................................................................................................................ 91
Forward speed ............................................................................................................................................. 91
Additional supply in forward travel ............................................................................................................... 91
Reverse........................................................................................................................................................ 91

Travel control spool...................................................................................................................... 92


Replenishing system (Nos. 13 and 14) ....................................................................................... 93
Description ................................................................................................................................................... 93

Travel oil motor type A6VM for 25/30 km/h, (No. 102) ............................................................... 94
Description ................................................................................................................................................... 94
Downhill........................................................................................................................................................ 94

Travel oil motor (25 and 30 km/h) with disconnectable hydraulic 'Vgz'
adjustment (No. 102)..................................................................................................................... 95
Description ................................................................................................................................................... 95

Travel oil motor, travel brake valve (No. 102)............................................................................. 96


Description ................................................................................................................................................... 96

1st + 2nd Gear - Floating axle ......................................................................................................... 97

BRAKING, STEERING AND FAN CIRCUIT ................................................. 98


Schematic diagram ....................................................................................................................... 98
Braking, steering and fan circuit of the 20 km/h version .......................................................... 99
Steering system .......................................................................................................................... 100
Steering valve OSPQ 75/175 LS, No. 40................................................................................................... 100
Priority valve (Nos. 44)............................................................................................................................... 102

Fan circuit.................................................................................................................................... 104


Combined radiator with controlled fan drive (No. 7) .................................................................................. 105

Replenishing system (for 25 and 30 km/h version) (Nos. 13 and 14)..................................... 106
Replenishing system, description .............................................................................................................. 106

Brake system in superstructure and undercarriage with Nos. 40, 41, 43, 44........................ 107
Superstructure............................................................................................................................................ 107
Undercarriage ............................................................................................................................................ 107
Pedal brake valve (No. 41) ........................................................................................................................ 108

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5-8

HYDRAULICS

WX210 - WX240

UNDERCARRIAGE, STABILIZERS............................................................110
Schematic diagram ..................................................................................................................... 110
Description ................................................................................................................................................. 111

Stabilizer control spool .............................................................................................................. 112


Levelling blade cylinder (No. 115) ............................................................................................. 114
Description ................................................................................................................................................. 114

Outrigger cylinder (No. 116)....................................................................................................... 115


Description ................................................................................................................................................. 115

Stabilization variants .................................................................................................................. 116


Description ................................................................................................................................................. 116
Ignition switch-on ....................................................................................................................................... 116
Actuating the preselector switches ............................................................................................................ 116

Hydraulic circuit diagram undercarriage, Part number 4530235............................................ 118


Undercarriage with 25 (30) km/h axle, sheet 1 of 7 ................................................................................... 119
Undercarriage with 25 km/h axle, sheet 2 of 7 .......................................................................................... 120
Undercarriage with A2 stabilization with individual control, sheet 3 of 7 ................................................... 121
Undercarriage levelling blade A2 stabilization, sheet 4 of 7 ...................................................................... 122
Undercarriage A4 stabilization, sheet 5 of 7 .............................................................................................. 123
Undercarriage levelling blade A2 stabilization individual control, sheet 6 of 7 .......................................... 124
Undercarriage A4 stabilization individual control, sheet 7 of 7 .................................................................. 125

BOOM CYLINDER CIRCUIT ...................................................................... 126


Schematic diagram with regeneration circuit .......................................................................... 126
Description ................................................................................................................................................. 127

Control spool............................................................................................................................... 128


Description ................................................................................................................................................. 129

Pipe break protection valves (Nos. 202 and 210)..................................................................... 132


Description ................................................................................................................................................. 132

Boom check valve with emergency operation capability ....................................................... 134


Description ................................................................................................................................................. 134

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5-9

BUCKET CYLINDER CIRCUIT .................................................................. 136


Schematic diagram ..................................................................................................................... 136
Description ................................................................................................................................................. 137

Control spool............................................................................................................................... 138


Bucket parallel connection circuit ............................................................................................ 140
Description ................................................................................................................................................. 140

Restrictor non-return valve (No. 206)........................................................................................ 141


Description ................................................................................................................................................. 141

Ballcocks (No. 207) ..................................................................................................................... 142


Description ................................................................................................................................................. 142

STICK CYLINDER CIRCUIT WITH REGENERATION FUNCTION ........... 144


Schematic diagram ..................................................................................................................... 144
Description ................................................................................................................................................. 145

Control spool............................................................................................................................... 146


Stick check valve with emergency operation capability ......................................................... 147
Description ................................................................................................................................................. 148

ADJUSTING CYLINDER CIRCUIT WITH


PRESSURE COMPENSATOR AND RELIEF VALVE ................................ 150
Description ................................................................................................................................................. 151
Control spool .............................................................................................................................................. 152
Boom adjusting cylinder control spool with compensator .......................................................................... 154
Boom adjusting cylinder control spool with pressure relief valve .............................................................. 154

Pressure compensator for adjusting cylinder ......................................................................... 155


Function ..................................................................................................................................................... 155
Operation ................................................................................................................................................... 155
Adjusting cylinder activated ....................................................................................................................... 156

Pressure compensator, relief valve and LS pressure limiting valve ..................................... 157
Relief valve................................................................................................................................................. 158

Pipe break protection valve ....................................................................................................... 159


Description ................................................................................................................................................. 159

COMBINED FUNCTIONS........................................................................... 162


Parallel actuation of boom, bucket, adjusting and stick cylinder .......................................... 162
Description ................................................................................................................................................. 163

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 10

HYDRAULICS

WX210 - WX240

HYDRAULIC HAMMER CIRCUIT WITH


BOOM ADJUSTING EQUIPMENT ............................................................. 164
Schematic diagram ..................................................................................................................... 164
Description ................................................................................................................................................. 165

Hydraulic hammer control spool............................................................................................... 166


Electrical circuit diagram, hammer equipment ........................................................................ 168

HAMMER CIRCUIT WITH AUXILIARY FUNCTION


(BOOM ADJUSTING EQUIPMENT) .......................................................... 170
Schematic diagram ..................................................................................................................... 170
Hammer circuit with auxiliary function like shears or crusher
with boom adjusting equipment, description.............................................................................................. 171

Hammer / shears control spool ................................................................................................. 173


Hammer circuit with auxiliary function, e.g. shears ................................................................ 174
Electrical circuit diagram, hammer / shears equipment ......................................................... 175

SHEARS / CRUSHER CIRCUIT (BOOM ADJUSTING EQUIPMENT) ...... 176


Schematic diagram ..................................................................................................................... 176
Shears or crusher circuit with boom adjusting equipment, description...................................................... 177

Shears / crusher control spool .................................................................................................. 178


Electrical circuit diagram, shears equipment .......................................................................... 180

HYDRAULIC HAMMER CIRCUIT (MONOBLOCK BOOM EQUIPMENT) 182


Schematic diagram ..................................................................................................................... 182
Hydraulic hammer circuit with monoblock boom equipment, description .................................................. 183

Hydraulic hammer control spool............................................................................................... 184


Electrical circuit diagram, hammer equipment ........................................................................ 186

HAMMER CIRCUIT WITH AUXILIARY FUNCTION,


MONOBLOCK EQUIPMENT...................................................................... 188
Schematic diagram ..................................................................................................................... 188
Hammer circuit with auxiliary function like shears or crusher with monoblock equipment, description .... 189

Hammer / shears control spool ................................................................................................. 192


Hammer circuit with auxiliary function, e.g. shears with monoblock equipment................. 194
Electrical circuit diagram, hammer / shears equipment ......................................................... 195

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 11

SHEARS / CRUSHER CIRCUIT, MONO BOOM EQUIPMENT ................. 196


Schematic diagram ..................................................................................................................... 196
Shears or crusher circuit with monoblock boom equipment, description................................................... 197

Shears / crusher control spool .................................................................................................. 198


Electrical circuit diagram, shears equipment .......................................................................... 200

SLEWING SYSTEM ................................................................................... 202


Schematic diagram ..................................................................................................................... 202
Description ................................................................................................................................................. 203

Slewing pump A 4 VG 71 DE4D (No. 4) ..................................................................................... 204


Description ................................................................................................................................................. 207

Port valve plate of slewing pump A4 VG 56 DE4D................................................................... 208


Port valve plate of slewing pump A 4 VG 71 DE4D.................................................................. 209
Slewing pump valves.................................................................................................................. 210
Feed-pressure limiting valve (No. 15) ........................................................................................................ 210
Sekundrventil ........................................................................................................................................... 210
Pressure cut-off valve (No. 18) .................................................................................................................. 211

Feed-pressure limiting valve of slewing pump A 4 VG 71 DE4D............................................ 212


Secondary valve of slewing pump A 4 VG 71 DE4D ................................................................ 213
Slewing pump control unit......................................................................................................... 214
Description ................................................................................................................................................. 215

Pressure-control valve ............................................................................................................... 216


Description ................................................................................................................................................. 216

Slewing gearbox assembly (No. 15).......................................................................................... 217


Slewing gearbox (No. 15) .......................................................................................................................... 218
Oil motor..................................................................................................................................................... 219

Speed sensor B35.2.................................................................................................................... 220


Description ................................................................................................................................................. 220

Integrated holding brake ............................................................................................................ 221

GRAB ROTATION MECHANISM ............................................................... 222


Schematic diagram ..................................................................................................................... 222
Description ................................................................................................................................................. 222

Solenoid valve for grab rotation (No. 231)................................................................................ 223


Description ................................................................................................................................................. 223

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 12

HYDRAULICS

WX210 - WX240

CONTROL

40000307-en

Introduction
The description of the machine control is divided
into 3 parts:
- Automotive electrical system
- Electronic systems with
the central electronic unit,
the electro-hydraulic pilot control and
the electronic load-limit regulation.
- Hydraulic system described according to the
power flow in the machine and the individual
functions and combined functions.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

HYDRAULIC SYSTEM

5 - 13

40000309-en

Overview
The hydraulic system consists of several circuits:
the pilot-control circuit, the working hydraulics circuit, the slewing circuit, the braking and steering
circuit and an optional auxiliary circuit.
The pilot-control circuit governs the pump control,
the load-limit regulation, the control spool adjustment, the switching circuits of the superstructure
and undercarriage control.
The working circuit supplies the working equipment, the undercarriage stabilization, the travel
drive and the auxiliary units with oil.
The slewing circuit is a separate circuit to ensure
slewing of the supersturcture.
Another circuit supplies the brake system, steering
system and the radiator fan drive.
The optional auxiliary circuit controls the grab rotation motor, the slewable trenching backhoe bucket
or other tools.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 14

HYDRAULICS

WX210 - WX240

Working, slewing and pilot-control circuits in the superstructure

40000533-en

10

5.1
5.2

5.3
5.4

15
5.5
5.6
5.7
2
13
17
4.1
11
3

12

16
4
1

14

19

4.2

18
Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 15

Legend
The variable displacement twin pumps P1 and P2
draw in hydraulic oil from the hydraulic reservoir.

Diesel engine

Hydraulic reservoir

Air-intake line

Variable displacement twin pump:

4.1

Pressure line of pump 1

4.2

Pressure line of pump 2

Control block with control spools for:

5.1

Travelling

5.2

Stabilizers

5.3

Boom

5.4

Backhoe bucket

5.5

Stick

5.6

Adjusting cylinder

5.7

Hammer/shears (optional)

Rotor

Boom cylinder

Adjusting cylinder

Stick cylinder

10

Bucket cylinder

11

Return-flow line

12

Hydraulic oil cooler

13

Return-flow filter

14

Slewing pump

15

Slewing motor

16

Pilot-control pump

17

Pilot-control unit

18

Steering and fan pump

19

Brake and grab rotation pump

The pressure line of pump 1 is flange-mounted on


the right side of the control block, viewed in the
sense of driving.
The oil from pump 1 flows in succession to the
travel control spool, the boom control spool, the
bucket control spool, the stick control spool and on
through the reservoir channel, hydraulic oil cooler
and return-flow filter back into the reservoir.
The pressure line of pump 2 is flange-mounted on
the left side of the control block. The oil from pump
2 flows in succession to the auxiliary control spool
for hammer/shears, the adjusting cylinder control
spool, the stick cylinder control spool, the bucket
control spool, the boom control spool, the stabilizer
control spool and on through the reservoir channel,
hydraulic oil cooler and return-flow filter back into
the reservoir.
Pumps P 1 and P 2 supply the oil depending on
control spool position to the travel motor and the
cylinders. The return oil flows via differential pressure valves and, depending on viscosity, through
the oil cooler or directly through the return-flow
filter back into the reservoir.
The slewing circuit is a closed hydraulic circuit.
The pump discharges directly to the oil motor and
the returning oil flows back to the reservoir. Oil
losses due to leakage are supplemented by an
integrated auxiliary pump. The auxiliary or feed
pump draws in oil from the hydraulic reservoir and
maintains the pressure inside the closed circuit.
The different superstructure slewing directions are
accomplished by reversing the pumping direction.

Oil flow through control block


Pump 1

Pump 2

Travel motor

Hammer/Shears

Boom cylinder

Adjusting cylinder

Bucket cylinder

Stick cylinder

Stick cylinder

Bucket cylinder

The pilot-control pump draws in oil from the variable displacement twin pump housing. The pilot oil
feeds the pilot-control unit with the pressurelimiting function. Excess oil not needed for control
actions flows back to the reservoir via the pressure-limiting valve. After limiting, the pilot pressure
is made available to the switching circuits, the control block for control spool variation and to the undercarriage switching circuits.

Boom cylinder
Stabilization
Tank

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 16

HYDRAULICS

WX210 - WX240

Working, travel and pilot-control circuits in the undercarriage

40000323-en

8
5

12
11
9
4
6
10

3
2
1

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

Legend
1.

Rigid axle

2.

Switchable gearbox

3.

Travel oil motor with travel brake


valve

4.

Cardan shaft

5.

Steering and floating axle

6.

Rotor

7.

Outrigger cylinders

8.

Levelling blade cylinders

9.

Valve block, stabilizer preselect

10.

Control block

11.

Steering cylinder

12.

Floating-axle cylinder

HYDRAULICS

5 - 17

The working circuit in the undercarriage supports


the stabilizing function. The oil from pump 2 flows
through the rotor to the valve block where the oil
path to the stabilizing cylinders can be preselected.
Further stabilizing variants not shown may enlarge
the range of application.
The travel circuit is supplied with oil from pump 1.
The volume flow passes from the travel control
spool through the rotor to the travel oil motor. The
return-flow oil flows through the travel brake valve,
the rotor and the control block back to the reservoir.
The pilot-control pressure is available at the control
block as switching pressure for the parking brake,
the gearshift, the floating-axle support and the
creep-speed function of the travel oil motor.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 18

HYDRAULICS

WX210 - WX240

Hydraulic circuit diagram superstructure

40000534-en

Hydraulic circuit diagram WX210 with monoblock boom equipment - Part number 4530257
Hydraulic circuit diagram WX210 with boom adjusting equipment - Part number 4530256
Hydraulic circuit diagram WX240 with monoblock boom equipment - Part number 4530259
Hydraulic circuit diagram WX240 with boom adjusting equipment - Part number 4530258

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Hydraulic circuit diagram WX210 with monoblock boom equipment

Fig. 1
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 19

5 - 20

HYDRAULICS

Hydraulic circuit diagram WX210 with boom adjusting equipment

Fig. 2
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

WX210 - WX240

HYDRAULICS

Hydraulic circuit diagram WX240 with monoblock boom equipment

Fig. 3
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 21

5 - 22

HYDRAULICS

Hydraulic circuit diagram WX240 with boom adjusting equipment

Fig. 4
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

WX210 - WX240

HYDRAULICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 23

5 - 24

HYDRAULICS

WX210 - WX240

Hydraulic circuit diagram undercarriage, Part number 4530235

40000325-en

Legend
75. Hydraulic rotor with 10 channels
76. Electric rotor with 16 slip rings
100. Travel drive consisting of:
rigid axle ASP100/125
101. Multiple-disk speed-change gearbox
102. Travel oil motor A 6 VM HA with travel brake valve MHB for 20 km/h axle
102. Travel oil motor A 6 VM HA with travel brake valve MHB and adjustment with shutoff only for 25 km/h or 30 km/h axle
104. Nitrogen accumulator for parking brake action delay in conjunction with restrictor 1 mm
105. Control block consisting of:
solenoid valve Y21.2 for creep speed selection
solenoid Y62 for floating-axle support
solenoid Y16 for parking brake with emergency actuation
solenoid Y21.4 for shifting gears
106. Pressure switch S16.1 for parking brake pilot lamp, opening pressure = 30 bars
107. Solenoid valves Y48.3 and Y48.4 for outrigger individual control, sheet 3 of 7
107. Solenoid valves Y48.1 and Y48.4 for levelling blade/outrigger switch-over, sheet 4 of 7
107. Solenoid valves Y48.1 and Y48.4 for switching of stabilization right-hand side / left-hand side, sheet 5 of 7
108. Solenoid valves Y48.1, Y48.3 and Y48.4 for levelling blade / outrigger individual control, sheet 6 of 7
109. Solenoid valves Y48.1, Y48.2, Y48.3 and Y48.4 for outrigger individual control, sheet 7 of 7
110. Steering and floating axle ALPP100/125
111. Floating-axle cylinder with integrated shutoff valve and restrictor non-return valves
115. Levelling blade cylinder
116. Ourigger cylinder

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 25

Undercarriage with 25 (30) km/h axle, sheet 1 of 7

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 26

HYDRAULICS

WX210 - WX240

Undercarriage with 25 km/h axle, sheet 2 of 7

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 27

Undercarriage with A2 stabilization with individual control, sheet 3 of 7

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 28

HYDRAULICS

WX210 - WX240

Undercarriage levelling blade A2 stabilization, sheet 4 of 7

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 29

Undercarriage A4 stabilization, sheet 5 of 7

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 30

HYDRAULICS

WX210 - WX240

Undercarriage levelling blade A2 stabilization individual control, sheet 6 of 7

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 31

Undercarriage A4 stabilization individual control, sheet 7 of 7

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 32

HYDRAULICS

WX210 - WX240

DRIVE UNIT
Drive unit, schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000536-en

WX210 - WX240

HYDRAULICS

5 - 33

Elements

Description
The drive unit is essentially composed of the diesel engine, the multicircuit pump unit, the auxiliary pumps
and the hydraulic reservoir.
The diesel engine (1) is a CNH engine belonging to the New Engine Family series (NEF). It is a 6-cylinder
inline engine with exhaust turbocharger and downstream charge air cooler.
The multicircuit pump unit (2) is driven from the engine via a flexible coupling and comprises variable displacement twin pump (3) with integrated pilot-control pump and slewing pump (4).
A double gear pump (230) is mounted on the engine P.T.O. The first pump is provided for the slewing circuit,
the fan drive and the optional replenishment unit. The second pump feeds the braking circuit and the grab
rotation motor.
The hydraulic reservoir (20) supplies the pumps with clean and cooled oil. The variable displacement twin
pump (3) draws in oil through port S. The integrated pilot-control pump draws in oil from the housing of the
variable displacement twin pump. The auxiliary pump (feed pump) integrated in slewing pump (4) draws in oil
through a separate line.
The double pump draw in oil from the reservoir through an independent line.

2
3

230
4
Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 34

HYDRAULICS

WX210 - WX240

Multi-circuit pump unit (No. 2)

40000327-en

Power take-off for slewing


pump A 4 V

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 35

Multi-circuit pump unit, description

2
4

Fig. 4

The pump unit comprises a transfer gearbox, the


variable displacement twin pump, the slewing
pump and a pilot-control pump.
The transfer gearbox (1) is driven from the engine
via a flexible coupling.
Two of the four gears of the transfer box constitute
the drive of the variable displacement twin pump
(2). An intermediate gear drives the pilot-control
pump (3) and the PTO to the slewing pump (4).
The transmission ratio between the drive and the
variable displacement pump and the slewing pump
is 1.

The variable displacement twin pump (2) consists


of two axial piston pumps in bent-axis design
housed in the same casing. Each of the pumps
has its own output regulator with which the discharge volume can be varied independently of the
other pump.
The pilot-control pump (3) is a gear pump.
The slewing pump (4) is an axial piston pump in
swash-plate design. The tilting angle of the swashplate determines the superstructure slewing speed.
The tilting direction of the swash-plate determines
the slewing direction of the superstructure.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 36

HYDRAULICS

WX210 - WX240

Variable displacement twin pump A8VO (No. 3)

40000328-en

A2
7

A1

A1

3
5
4

A2

Fig. 1

Legend

Slide surface for control lens

Suction port

Tappet

Cylinder drum with axial piston

Control piston of the adjusting mechanism

Center tappet

Adjusting angle of cylinder drum

Spring assembly

A1

Pressure port of pump 1

Control lens with spherical bottom

A2

Pressure port of pump 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Variable displacement twin pump A8VO,


description
The variable displacement twin pump consists of
pump 1 and pump 2. Each of the pumps has its
own output regulator with which the pumps can be
adjusted independently of the other pump.
Due to the bent-axis design, rotational movement
is converted to piston stroking. On one side, oil is
sucked in by the backward movement of the axial
pistons in the cylinder drum (2), whereas the oil
sucked in is displaced on the other side by the
forward movement of the axial pistons in the cylinder drum (2).
The cylinder drum is guided by a center tappet (3)
taking support in the ball cup and exerts a certain
prestress on the spherical control lens (5) by
means of the springs (4). The prestress exerted by
the spring assembly enhances the centering pressure of the cylinder drum on the control lens and
improves the sealing of the rotating cylinder drum
with respect to the stationary control lens on the
spherical surface especially at low pressures
where the hydraulic contact pressures are not yet
very high.

5 - 37

Port designations

A, B

working connections

suction port

A3

pressure port of pilot-control pump

R1, R3

vents

R2

oil drain

X1

load sensing pressure ports

X3

control pressure from load-limit regulation

Y3

pilot-control pressure after engine start

measuring point for pressure in control


chamber

M1,M2

closed ports

M3

control pressure measuring point

Symbol

The control lens (5) is mechanically connected to


the control piston (8) via a tappet (7). The movement of the control piston (8) is transferred to the
control lens (5), guiding the control lens together
with the cylinder drum (2) along the slide surface
(6) and thus adjusting its angle with respect to the
drive shaft.
The variation of the adjusting angle results in a
change of the piston stroke in the cylinder drum
and thus in a change of the discharge flow of the
pump.

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 38

HYDRAULICS

WX210 - WX240

Drive unit, variable displacement twin pump output regulator (No. 3)

40000329-en

Drive unit, variable displacement twin


pump - output regulator (No. 3)
The output regulator varies the pump discharge
flow depending on the:
- load-sensing pressure
- pump pressure
- load-limit regulator control pressure

These three pressures act simultaneously on the


output regulator and may therefore also be superposed. The control pressure has priority and prevents the diesel engine from being overloaded by
excessive power demands from the pumps.
When the diesel engine is stationary, pumps 1
and 2 are adjusted by the spring (4) to maximum
angle.
When the engine is running, the integrated pilotcontrol pump supplies oil to pump regulator port
Y3 which acts via an internal channel on both output regulators.
The pressure at port Y3 passes through shuttle
valves past control piston (5) into control chamber
A under control piston (8). Both pumps swivel to
Vgmin.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 39

Output regulation by load-sensing pressure

X1

1
Y3

5
HD
X3

3
2
4
8
6

control chamber
pressure

Y3

Pilot-control pressure

X1

Load-sensing pressure

HD

Pump pressure

X3

Control pressure, load-limit

Control chamber pressure

7
A

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 40

HYDRAULICS

WX210 - WX240

Output regulation by load-sensing pressure, description


The level of the load-sensing pressure is dependent on the excursion of the control levers or pedals.
A short lever excursion results in a low loadsensing pressure and vice versa. The loadsensing pressure acts on port X1 raising step
piston (10) partly or completely against the force
of spring (11). The forces of the adjusting springs
(2+3) lift the adjusting elements, i.e. control piston
(5), pin (12), step piston (13) with control sleeve
(14) and pin (15) against control piston (10) displaced by the load-sensing pressure. A control
edge at control piston (5) opens towards the housing with oil now flowing out of control chamber A.
The pump is adjusted by the adjusting springs
(2+3) towards Vgmax and thus to a higher discharge flow.
The adjusting angle corresponding to the loadsensing pressure is reached, when an equilibrium
of forces is established between the adjusting
springs (2+3) and the adjusting force at control
piston (10). A change of the load-sensing pressure entails a change of the adjusting force at
control piston (10) with the regulator responding to
this condition by adapting the discharge flow accordingly. When the control levers and pedals are
brought to neutral position, the load-sensing pressure diminishes and the regulator swivels the
pump back to Vgmin.

The diagram illustrates the relationship between


load-sensing pressure and discharge flow.
The characteristic curve therefore represents the
discharge flow change as a function of the loadsensing pressure.

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 41

Output regulation by pump high pressure


16
X1
11

10
15
14
13
12

19

17
18

Y3

X3
5

control chamber
pressure

HD
A

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 42

HYDRAULICS

Regulation by pump high pressure, description


The output regulator controls the pump discharge
flow as a function of the pump high pressure in
such a way that a predefined drive power is not
exceeded.

WX210 - WX240

Example 1

At a pressure of 140 bars, the regulator reduces


the oil flow rate to 127 l/min. In this case, only
adjusting spring (2) is engaged.

The mechanical base power output adjustment for


each regulator is performed with setscrew (19).
This base power setting can be overridden by
variable control pressures at port X3 depending
on the power mode preselected.
With pump pressures below the power setting and
a corresponding load-sensing signal at port X1,
the pump is forced by the adjusting springs (2+3)
to the Vgmax position.
The pump works with maximum discharge flow for
fast working movements.
The rising pump pressure, e.g. in the event of
excavating movements, acts on the measuring
surface of the step piston (13) and thus via pin
(12) and control piston (5) against power spring
(17). When the hydraulic force exceeds the spring
force, control piston (5) opens its control edge so
that pump pressure passes into control chamber
A below adjusting piston (8) which swivels the
pump back. The hydraulic force raises adjusting
piston (8) at first against adjusting spring (2) and
then, with pressure increasing further, additionally
against adjusting spring (3). The pump adjusting
process ends, when the forces of the adjusting
springs and the hydraulic force under the adjusting piston are in equilibrium. The control piston (5)
is raised again, closing the control edge in the
process and thus the connection with adjusting
piston surface A. The result is a discharge flow
corresponding to the pump high pressure in accordance with the spring characteristic in the output diagram. A changing high pressure value results in a new control cycle along the spring characteristic of the output diagram. This ensures that
the drive power is not exceeded.

Fig. 4

Example 2

At a pressure of 220 bars, the regulator reduces


the oil flow rate to 77 l/min. In this case, both adjusting springs (2+3) are engaged.

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 43

Output regulation by load-limit control


16
X1
11

10
15
14
13
12

19

17
18

Y3

X3
5

control chamber
pressure

HD
A

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 44

HYDRAULICS

WX210 - WX240

Description

Example 3

The sum of the installed hydraulic power of all


pumps exceeds the engine power installed. The
electronic load-limit regulation now intervenes in
the output regulation of the variable displacement
twin pump in such a way that the discharge flow of
the pumps is reduced until the total hydraulic
power absorbed corresponds to the engine power
supplied.

With a pump pressure of 210 bars and a control


pressure at X3 of 25.8 bars, the pump discharges
a flow of 120 l/min.

For output regulation of the variable displacement


twin pump, the pump regulators are fed with a control pressure from the load-limit regulation which
rises when the engine is overloaded and which
drops when the engine loading diminishes.
This variable control pressure acts through port X3
on both pump regulators. The step pistons (13) of
both pump regulators receive pressure on the upper measuring surface, where a downward hydraulic force is generated. This force is added to the
hydraulic force existing due to the pump high pressure at the lower measuring surface of step piston
(13).
Since the pressures of pump 1 and pump 2 are
seldom at the same level during working, the adjusting forces resulting at the output regulators
lead to a different control behaviour.
The adjusting force resulting from the control pressure and the pump high pressure acts against the
force of power spring (17). When the adjusting
force prevails, control piston (5) is displaced
downwards against the force of the adjusting
springs (2+3) with its control edge opening towards
control chamber A. The adjusting piston (8)
changes the angle of the pump and thus its discharge flow until an equilibrium of forces is established in the output regulator.

Fig. 7

Example 4

With a high pressure of 210 bars and a control


pressure increase at X3 of 34 bars, the pump discharges only 80 l/min .

The drive power for both pumps is thus adapted to


the engine power even with different control actions of the individual pumps.

Fig. 8

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Pilot-control pump (No. 3)

5 - 45

40000330-en

pilot-control port A3
1

Fig. 1

Legend

Description

Gear pump

The gear pump supplies oil to the pilot-control circuit.

Seals

Variable displacement twin pump

The pump is driven from the transfer gearbox of


the variable displacement twin pump. In operation,
the gear pump draws in oil from the housing of the
variable displacement twin pump. The two gearwheels in mesh convey the fluid between the
tooth-flanks from the suction side to pressure port
A3 and from there further into the pilot-control system.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 46

HYDRAULICS

WX210 - WX240

Drive unit, double gear pump (No. 230)

40000584-en

3
2

1
Fig. 1

Legend
1

Double gear pump

Seal

Pump drive

Gear casing

Description
One pump of the double pump supplies oil to the
steering circuit and the fan drive. The second
pump supplies oil to the braking circuit and to the
optional grab rotation drive.

The pump is designed as a double gear pump. It is


driven from the PTO of the diesel engine. The
pump receives hydraulic oil via a common suction
port.
Gear pumps are essentially composed of two
gearwheels in mesh enclosed in a housing. One of
the gearwheels is driven by a through-shaft
whereas the second wheel is driven via the toothing. The fluid under pressure is entrapped between
the tooth flanks and conveyed on the outside along
the housing walls from the suction side to the
pressure side and then discharged into the system.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Drive unit, Hydraulic reservoir with attachments (Nos. 20-24)

5 - 47

40000538-en

Fig. 1

Legend
1

Reservoir

Return-flow filter element

Breather filter

Oil drain plug

Oil level indicator

Pressure switch S15

Temperature sensor R14

Screw plug

Description
The hydraulic reservoir serves the purpose of storing hydraulic oil. It is also equipped with a filter
chamber for the return-flow filter.
The cover in the center of the reservoir with the
breather filter closes the inspection opening.

Oil pressure switch S15 on the filter chamber


monitors the filter operation. The switch contact
closes when the filter element is contaminated and
when the back-pressure becomes inadmissibly
high, triggering an optical and an acoustic warning
signal.
The breather filter protects the oil against ambient
influences. An integrated double-acting valve ensures on the one hand that the atmospheric pressure can get into the resevoir when the oil level
descends until the admissible pressure is reached
and on the other hand that the pressure in the reservoir is limited when the volume changes due to
oil heating or after retracting of working cylinders.
The temperature sensor R14 is an NTC resistor
and senses the hydraulic oil temperature. The
temperature signal is transmitted to the load-limit
regulator for temperature monitoring purposes.

Various connecting ports for return-flow lines to the


filter chamber, for return-flow lines below the filter
chamber and for the suction line are welded into
the outside of the reservoir wall. The oil drain plug
is located at the bottom.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 48

HYDRAULICS

WX210 - WX240

CONTROL BLOCK

40000539-de

Control block, rear view

Fig. 1

Legend
1
Primary pressure-limiting valve pump 1
2
Primary pressure-limiting valve pump 2
3
LS pressure-limiting valve
4
Relief valve
5
Load-holding valves pump 1
6
Load-holding valves pump 2
7
Plug
P1
Port pump 1
M1
Pressure measuring point pump 1
B211 Pressure sensor pump 1 at port S1
T1
Tank connection to reservoir
T2
Tank connection to oil cooler
L
Leakage line connection (pressureless to tank)
PF
Pilot-control pressure port (only for travel function)
A1.1 Replenishing port during travelling (only with 25 km/h and 30 km/h versions)
B239 Pressure sensor at port MS
SV
Secondary pressure-limiting valve for adjusting cylinder piston side
Y20xa Proportional valves for upper caps
Y20xb Proportional valves for lower caps

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 49

Control block, front view


B1

B2-Kf

B3-Kf
3

B4-Rf

B5-Rf

B6-Kf

1
2
10
M2
B210
P2

B10

DW

DW

13

13

11
A1

A2-Rf

12
A3-Rf

4
A4-Kf

6
A5-Kf

9
A6-Rf

Fig. 2

1
2
3
4
5
6
7
8
9
10
11
12
13
DW
P2
M2
B210
B10
A1/B1
A2/B2
A3/B3
A4/B4
A5/B5
A6/B6

Primary pressure-limiting valve pump 1


Primary pressure-limiting valve pump 2
Secondary pressure-limiting valve boom cylinder extend
Secondary pressure-limiting valve boom cylinder retract
Secondary pressure-limiting valve bucket cylinder retract
Secondary pressure-limiting valve bucket cylinder extend
Secondary pressure-limiting valve stick cylinder retract
Secondary pressure-limiting valve stick cylinder extend
Secondary pressure-limiting valve adjusting cylinder retract
Replenishing valve reverse travel
Replenishing valve forward travel
Bucket parallel valves
Plug
Pressure compensator for travel and adjusting cylinder functions
Port pump 2
Pressure measuring point pump 2
Pressure sensor pump 2 at port S2
Pressure sensor for automatic gearshift
Ports for travel oil motor, forward/reverse
Ports for stabilizing cylinders, retract/extend
Ports for boom cylinder, retract/extend
Ports for bucket cylinder, retract/extend
Ports for stick cylinder, retract/extend
Ports for stick adjusting cylinder, retract/extend

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 50

HYDRAULICS

WX210 - WX240

Control block, bottom view

Y206a

PV

Y205a

Y206b

Y204a

Y205b

Y203a

Y204b

Y202a

Y203b

Y201a

Y202b

Y201b

Fig. 3

In following tables there are the solenoid valves and the corresponding working functions:
No.
Y201a
Y201b
Y202a
Y202b
Y203a
Y203b
Y204a
Y204b
Y205a
Y205b
Y206a
Y206b
PV

Description
Forward travel
Reverse travel
Stabilizing cylinder retract / stabilizers up
Stabilizing cylinder extend / stabilizers down
Boom cylinder retract / lower equipment
Boom cylinder extend / raise equipment
Bucket cylinder extend / fill bucket
Bucket cylinder retract / empty bucket
Stick cylinder extend / lower stick
Stick cylinder retract / raise stick
Boom adjusting cylinder retract / raise upper boom section
Boom adjusting cylinder extend / lower upper boom section
Pilot-pressure port for cylinder functions

IMPORTANT:

In machines with monoblock equipment, the boom adjusting cylinder control block can be equipped with
proportional valves Y206a and Y206b for auxiliary equipment such as hydraulic hammer and/or shears.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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5 - 51

5 - 52

HYDRAULICS

WX210 - WX240

Control block for monoblock boom equipment with hammer / shears

40000540-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 53

Description

Oil flow from pump 2

In the description of the neutral circuit and of the


other functions, the drive unit has been represented in a simplified way. Pumps 1 and 2, the
direct return to the filter and the return through the
cooler (7) to filter (21) are only outlined. The following explanations refer to the neutral position of all
control spools in the 6-spool control block.

The oil flows through port P2 into the control block


and then at first to pressure measuring point M2
and the primary pressure-limiting valve.

Oil flow from pump 1


The oil flows through port P1 into the control block
and then to pressure measuring point M1 and the
primary valve for the pressure relief of pump 1.
The oil flows through the two parallel channels P1
and P01 to the control spools and the valves.
Channel P1 directs the oil flow through a valve of
the bucket parallel circuit to the bucket control
spool.
Channel P01 directs the oil flow to the travel spool
with a branch-off ahead of the spool to a load- or
pressure holding valve. The load-holding valve
opens and the oil is available for further work at the
travel spool. The oil flow by-passes the stabilizer
spool and reaches the boom spool. A branch-off
ahead of the spool directs the oil flow also via another load-holding valve to the boom spool. The oil
flows then to the bucket spool and is also available
to the bucket spool via a load-holding valve. The
oil passes then to the stick spool with a branch-off
directing the oil also via a load-holding valve to the
stick spool. The oil flow by-passes the adjusting
spool (neck spool) and reaches the tank channel.

Two parallel channels P2 and P02 direct the oil


flow through the control block.
Channel P2 directs the oil flow to the relief valve,
the pressure compensator and to the bucket parallel circuit valve.
The relief valve and the pressure compensator are
part of the adjusting spool circuit.
They are controlled by the load pressure of the
adjusting cylinder and ensure that a load-pressureindependent discharge flow supplies the adjusting
cylinder. The excess oil from pump 2 that is not
used by the adjusting cylinder is available via the
relief valve to other functions.
The valve of the bucket parallel circuit opens and
the oil flow from pump 2 joins the oil flow from
pump 1.
Both pumps supply partial oil volumes for the
bucket parallel circuit.
Channel P2 passes through the blanking plate (55)
and continues as channel P02 through the control
block.
In zero position of the adjusting spool, the oil flows
to the stick spool with a branch-off ahead of the
spool via a load-holding valve to the stick spool.
The oil passes to the bucket spool with a loadholding valve opening the passage for the oil flowing to the bucket spool. The next spool to receive
oil is the boom spool. This oil is also available via a
load-holding valve to the boom function.
The oil flows then to the stabilizer spool and is also
available to this spool via another load-holding
valve. The oil from pump 2 then flows past the
travel spool into the tank channel.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 54

HYDRAULICS

WX210 - WX240

Control block for boom adjusting equipment with hammer / shears

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 55

Description

Oil flow from pump 2

In the description of the neutral circuit and of the


other functions, the drive unit is represented in a
simplified way. Pumps 1 and 2, the direct return to
the filter and the return through the cooler (7) to
filter (21) are only outlined. The following explanations refer to the neutral position of all control
spools in the 7-spool control block

The oil flows through port P2 into the control block


and then at first to pressure measuring point M2
and the primary pressure-limiting valve.

Oil flow from pump 1


The oil flows through port P1 into the control block
and then to pressure measuring point M1 and the
primary valve for the pressure relief of pump 1.
The oil flows through the two parallel channels P1
and P01 to the control spools and the valves.
Channel P1 directs the oil flow through a valve of
the bucket parallel circuit to the bucket control
spool.
Channel P01 directs the oil flow to the travel spool
with a branch-off ahead of the spool to a load- or
pressure holding valve The load-holding valve
opens and the oil is available for further work at the
travel spool. The oil flow by-passes the stabilizer
spool and reaches the boom spool A branch-off
ahead of the spool directs the oil flow also via another load-holding valve to the boom spool. The oil
flows then to the bucket spool and is also available
at the bucket spool via a load-holding valve. The
oil passes then to the stick spool with a branch-off
directing the oil also via a load-holding valve to the
stick spool. The oil flow by-passes the adjusting
spool (neck spool) and reaches the tank channel.

Two parallel channels P2 and P02 direct the oil


flow through the control block.
Channel P2 directs the oil flow to the relief valve,
the pressure compensator and to the bucket parallel circuit valve.
The relief valve and the pressure compensator are
part of the adjusting spool circuit.
They are controlled by the load pressure of the
adjusting cylinder and ensure that a load-pressureindependent discharge flow supplies the adjusting
cylinder. The excess oil from pump 2 that is not
used by the adjusting cylinder is available via the
relief valve to other functions.
The valve of the bucket parallel circuit opens and
the oil flow from pump 2 joins the oil flow from
pump 1. Both pumps supply partial oil volumes for
the bucket parallel circuit.
Channel P2 passes into the supplementary control
block (52) to another pressure compensator, which
is assigned to the hammer/shears function.
Together with the pressure compensator, the ESXcontrolled solenoid valve Y239.2 offers the possibility of selecting four different power levels, e.g.
for four hydraulic hammers of different size.
A bore in cover plate (55) ensures the connection
between channel P2 and channel P02. In zero
position of the adjusting spool, the oil flows past
this spool to the stick spool with a branch-off
ahead of the spool via a load-holding valve to the
stick spool. The oil passes to the bucket spool with
a load-holding valve opening the passage for the
oil flowing to the bucket spool. The next spool to
receive oil is the boom spool. This oil is also available via a load-holding valve to the boom function.
The oil flows then to the stabilizer spool and is also
available to this spool via another load-holding
valve. The oil from pump 2 then flows past the
travel spool into the tank channel.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 56

HYDRAULICS

WX210 - WX240

Control block valves

40000542 -de

Primary pressure-limiting valves with pressure sequence stage (1)


Description
The primary valves limit the working pressure of
pump 1 and pump 2.

The pressure sequence stages permit higher pump


pressures for operation with the power assist or
power boost function.
The primary valves are located in the pump channel of the corresponding pump ahead of the control
spools.
By design, these valves are pilot-operated pressure-limiting valves with a virtually flow-independent response.
The high-pressure is admitted to main piston (2)
and passes at the same time through the center
bore behind the main piston into the cavity with
spring (3) and from there through a restrictor below
pilot valve (4). The pilot valve is kept closed by
spring (5) as long as the opening pressure is not
reached. When the opening pressure is reached,
the pilot valve is lifted off its seat, the spring cavity
is pressure-relieved and the main piston opens the
passage to the tank channel of the control block.
The sequence stage with stroke-adjustable piston
(9) permits two different opening pressures.

Fig. 1

Pilot-control pressure from Y63


12

11
8
10
7

The lower opening pressure is determined by the


force of spring (5) without pilot pressure from Y63.

The high opening pressure is reached with the


help of pilot pressure from Y63 on piston (9). In this
case, piston (9) is driven to the stop into threaded
sleeve (8), pushing at the same time plunger (7)
against spring (5). The spring force increases and
greater high pressure is required to overcome this
force.

5
4
3

After pressure relief of piston (9) by Y63, spring (5)


is decompressed so that the pump pressure is
limited by the lower opening pressure.

Tank
channel

1
High pressure

Fig. 2

No.
1
2
3
4
5
6

Description
Valve housing
Main piston
Spring cavity with spring
Pilot-control piston, pilot valve
Spring
Housing of sequence stage

No.
7
8
9
10
11
12

Description
Plunger
Threaded sleeve, adjustable
Piston
Lock-nut
Piston guide, adjustable
Lock-nut

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Tank channel preloading valves

5 - 57

Tank channel preloading valves (T1 and


T2), description
The return oil from the tank channel of the control
block must flow back to the hydraulic reservoir
through the parallel non-return valves in port T1
and in port T2. To open the valves, the valve poppets must be pushed backwards against the spring
forces.
As far as the valve in T2 is concerned, the cooler
flow resistance must be added to these forces.
This outflow resistance generates the preloading
pressure in the tank channel. The amount of the
preloading pressure is also determined by the return-flow volume. A large volume of oil requires a
great drain cross-section, which means that the
valve poppet must open further so that the spring
under the poppet is compressed more strongly.

Fig. 3

Tank channel

This preloading pressure ensures the oil supply of


the cylinders and the travel oil motor via the replenishing non-return valves.
The non-return valve in T1 is equipped with a 5-bar
spring whereas the valve in T2 is equipped with a
2-bar spring.
The amount of return oil drained through the valve
in T2, must overcome the force of the 2-bar spring
plus the viscosity-dependent cooler flow resistance. When the oil is cold, the overall resistance
is higher and part of the volume is drained through
the 5-bar valve in T1. The cooling oil volume is
regulated by the differential resistances in T1 and
in T2 depending on viscosity. reguliert.
The 5-bar valve in T1 protects in addition the radiator against inadmissibly high pressures.

Fig. 4

The by-pass bore, parallel to the valve in T2,


serves as a pressure relief for the tank channel
after engine stop.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 58

HYDRAULICS

WX210 - WX240

Secondary pressure-limiting valves with replenishing stage (SV)


Description
The secondary valves protect the cylinders and the
travel oil motor against inadmissibly high pressures
generated by the forces occurring when the machine is working. Peak loading is thus effectively
avoided.
The secondary valves protect the boom, bucket
stick and adjusting cylinders at their piston and rod
sides respectively.

SV

The travel oil motor is equipped with one secondary valve on each side.
The integrated replenishing stage receives pressurized oil from the preloaded tank channel which
supports filling of the components in the event of
insufficient oil in the cylinders or in the travel oil
motor.
By design, the secondary valve is a pilot-controlled
pressure-limiting valve maintaining the preset
opening pressure almost independent of the flow.

Fig. 5

The high pressure as reaction pressure from the


cylinders or from the oil motor is admitted to main
pistons (2). At the same time, it passes through the
central bore into spring cavity (3) where it is available at pilot piston (4). The adjustable force of
spring (5) maintains pilot control piston (4) closed
until the hydraulic force under pilot control piston
(4) is greater. In this case, the spring cavity is
pressure-relieved and main piston (2) opens towards the tank channel. The pressure peak escapes against the preloading pressure of the tank
channel back into the reservoir.

When the pressure is lower than the opening pressure, pilot control piston (4) closes again with a
force building up in the spring cavity behind main
piston (2) which recloses the valve.

In the event of oil shortage in the cylinder or in the


oil motor, the force of the preloading pressure acting on rod side A lifts main piston (2) and the preloaded oil from the tank channel flows into the cylinder chambers or to the oil motor for filling purposes.

6
5
4

Tank
channel

2
1

A
High pressure
Fig. 6

No.
1
2
3
4
5
6
7
A

Description
Valve housing
Main piston
Spring compartment with spring
Pilot control piston, pilot valve
Spring
Valve adjusting screw
Lock-nut
Rod side

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

Proportional valves for control spool


adjustment

HYDRAULICS

5 - 59

Description
The proportional valves for bilateral spool adjustment are located in the same housing.

Y20Xb Y20Xa

They serve the purpose of converting the electrical


control current from the ESX into a pilot control
pressure.
The pilot control pressure is available at port P and
at both proportional valves only after a cylinder or
a travel function has been initiated.
If the valve with identification letter a is energized,
the pilot control pressure passes into the upper
cap. The control spool would be moved downwards.
The valve with identification letter b lets pilot pressure flow into the lower cap with the control spool
being adjusted upwards.

Symbol

Any movement of the joysticks or pedals is detected by the ESX which sends a lever- or pedaldependent control current to the corresponding
proportional valve.
In neutral position of all control elements, both pilot
control caps are linked with the leakage oil channel
L via the control pistons in the proportional valves.
Leakage oil then flows pressureless back to the
reservoir.

Fig. 7

After activation of the ignition and after booting of


the electronic system, a PWM signal of approx.
100 mA is present at the solenoids even without a
function being actuated to detect possible faults
as, for instance, a broken cable or a short-circuit to
ground.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 60

HYDRAULICS

Pressure sensors

WX210 - WX240

Description
The pressure sensor converts a hydraulic pressure
into a current signal in the mA range.
The pressure sensors B210 for pump 2, B211 for
pump1 and B239 for the load-sensing pressure are
required for calibration of the electro-hydraulic pilot
control.
Pressure sensor B10 is necessary for the automatic gearshift.
Pressure sensor B74 senses the pressure on the
piston side of the boom cylinders. Its current signal
is used for the regeneration function during boom
lowering.

Pin assignment

Fig. 8

PIN1

0 volt / signal to EXS

PIN2

GND

PIN3

+voltage from CU

Diagram
mA
20

Fig. 9

4
0

450 bar

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 61

5 - 62

HYDRAULICS

WX210 - WX240

PILOT-CONTROL SYSTEM

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000545-de

WX210 - WX240

HYDRAULICS

Pilot-control system, description


The pilot-control circuit supplies oil to the pilotcontrol unit with the solenoid valves of the pump
control, the load-limit regulation and the circuit
elements of the superstructure and undercarriage
control.

Pilot-control circuit in neutral position


The pilot-control pump supplies oil to the pilotcontrol unit which comprises the pressure-limiting
devices.
The pilot-control pressure limited in this way gets
to port Y3 of the variable displacement pump, adjusting both pumps towards Vgmin, but not to zero
flow, as both pumps receive a small amount of
load-sensing pressure via the pump control proportional valves Y241 and Y242 at ports X1. The
pumps swivel out to such an extent that each
pump sends a flow of flushing oil through the control block. This is achieved by ESX activation of
proportional valves Y241 and Y242 when the control elements are in neutral position.
Proportional valve Y10 of the load-limit regulation
is activated with high current from load-limit regulator A10, with maximum control pressure getting to
both pump regulators via port X3. This maximum
control pressure reduces the power consumption
of pumps 1 and 2 to minimum.
Solenoid valve Y113 of the pilot-control pressure
shut-off for the working and slewing functions is
without current, even after actuation of the pilotcontrol pressure lever in the left-hand control console.

5 - 63

Solenoid valve Y35 of the superstructure holding


brake is without current so that the multiple-disk
brake is blocked by spring force. Solenoid valve
Y35 is controlled from the ESX.
Solenoid valve Y290 of the pilot-control pressure
shutoff is without current.
The ESX actuates solenoid valve
Y290 when the travel pedal is depressed. Pilot-control pressure is
available at the proportional valves
of the travel control spool only after
the travel pedal has been depressed.

Solenoid valve Y63 of the power assist function is


actuated by the central electronic control unit CU.
When the valve is without current, the power assist
function is not operational.
The nitrogen accumulator at port S supplies the
pilot-control system after an engine stop to permit
depressurization of the hydraulic system or emergency lowering of the equipment. For this purpose,
the ignition must be on and the control unit must
be booted so that the corresponding solenoids can
be actuated and the pilot-control pressure get to
the control block.
The controlled non-return valve under the accumulator works as a pressure-holding valve as the
accumulated pressure drops quickly when the engine has been stopped.
Port A serves to supply control block (105) of the
undercarriage control.

The ESX actuates solenoid valve


Y113 only after a control lever has
been moved out of neutral position.
This means that pilot-control pressure is available at the proportional
valves of the control block and at
the proportional valves of the slewing pump only after a working function has been activated.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 64

HYDRAULICS

WX210 - WX240

Pilot control unit (nos. 60, 61, 63 and 64)

40000373-en

64 S290
61
63

64 S113.4

60

Y242
Y241

Y63 Y290
Y35
Y113
Y10

Fig. 1

Legend
60

Pilot control unit, base unit with four solenoid valves

61

Load-sensing unit with proportional valves


Y241 and Y242

63

Solenoid Y63 for power assist and


POWER BOOST functions

64

Pressure switch S113.4 for monitoring of


activation and deactivation of pilot control
pressure

64

Pressure switch S290 for monitoring of


activation and deactivation of the pilot
control pressure for travelling

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 65

Pilot control unit, schematic diagram

Fig. 2

Pilot control unit, description


The pilot control unit consists of a base unit with
flange-mounted solenoid valves.
The valve combination is supplied with oil from the
pilot control pump via port P:
The base unit (60) is equipped with an inlet filter
protecting the downstream components against
possible contamination.
The non-return valve behind the filter opens and
lets the oil flow to the pressure-reducing valve protecting the pilot control circuit. The excess oil
passes via port T pressureless to the hydraulic
reservoir (2).
The pilot control pressure limited in this way
passes through the pilot-operated pressure holding
valve to the nitrogen accumulator, to port A for the
undercarrige supply and to solenoid valve Y113.
The pilot pressure is moreover available at proportional Y10, at solenoid Y 35, at pressure measuring point M, at solenoid Y290 and at the flangemounted solenoids Y 63 (63) and the proportional
vavles Y241 and Y 242 (61).

The diaphragm accumulator is preloaded with nitrogen. In operation, the accumulator is loaded by
pilot-control pressure. The accumulated pressure
energy is available after engine stop to solenoid
valve Y 113 and to the undercarriage control.
When solenoid valve Y113 is energized, all cylinder functions can be pressure-relieved by means
of the accumulator pressure. This permits also an
emergency lowering of parts of the equipment.
The pilot-operated pressure holding valve below
the accumulator ensures that the accumulator
pressure is maintained and prevented from escaping towards the pilot control pump after engine
stop.
The pilot control pressure passes via port A of the
base unit through the hydraulic rotor (75) to the
control block (105) in the undercarriage.
The two pressure switches S113.4 and S290 (64)
check that the solenoids Y113 and Y290 are open
to the pilot pressure when energized and closed to
the pilot pressure when de-energized.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 66

HYDRAULICS

WX210 - WX240

Solenoid valves and their functions

40000374-en

Proportional valve Y10 of the load-limit


regulator

Fig. 2

Fig. 1

Legend
P

Pilot-control pressure

A3

Control pressure to power regulator

Tank connection, pressureless

Valve housing

Solenoid

Plunger

Control piston

Spring plate

Compensator spring

Emergency control

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WX210 - WX240

HYDRAULICS

5 - 67

Description

Emergency control

Proportional valve Y 10 is used as a signal converter. The valve converts electric control current
from the load-limit regulator into control pressure
for the output regulation of the working pumps. The
control pressure is proportional to the control current.

In the event of an electronic failure, the proportional valve is equipped with a mechanical emergency control device (7) with which control piston
(4) can be adjusted to maintain the machine functions. In the emergency mode, the machine can be
operated at reduced speed.

The valve housing (1) accomodates solenoid (2),


plunger (3) and control piston (4) with spring plate
(5) and adjusting spring (6).

When current flows through the solenoid, the magnetic force displaces the plunger and the control
piston against the force of the spring. The control
edge of the control piston opens a cross-section
through which the pilot pressure can partly pass to
port A3 as control pressure.
The control pressure thus generated builds up a
spring-assisted resetting force which displaces the
control piston backwards against the magnetic
force of the solenoid.
The flow cross-section at the control edge of the
control piston is open as long as the magnetic
force is higher. As long as the control edge is
open, the control pressure increases and the resetting forces increase as well.
The control edge is closed when the forces are in
equilibrium.
When less current flows through the solenoid, the
resetting forces press the control piston into a position creating a drainage cross-section towards the
tank. Through this opening, the control pressure is
reduced. The drainage cross-section closes after
the equilibrium of forces has been reestablished.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 68

HYDRAULICS

WX210 - WX240

Solenoids Y35 and Y113


64 S290
61
63

64 S113.4

60

Y242
Y241

Y63 Y290
Y35
Y113
Y10

Fig. 3

Solenoid valve Y35 for the superstructure


holding brake in the slewing gearbox

Solenoid valve Y113 for pilot pressure


activation and deactivation

Description

Description

Solenoid valve Y35 actuates the holding brake in


the slewing gearbox. In zero position, the holding
brake is connected via port A2 to tank port T of
the base unit.

Solenoid valve Y113 switches the pilot pressure


for all working functions except travelling.

The brake is then without pressure and blocked


by spring force.
When the solenoid is engergized, the control piston is displaced and the pilot pressure gets to the
piston of the multi-disk brake. The piston pushes
the springs back and the brake disks are released
so that the superstructure can be slewed.
Solenoid valve Y 35 is additionally equipped with
a mechanical emergency control device.
In the event of electrical failure, the screw provided can be turned down completely. The control
piston is then mechanically displaced so that the
pilot pressure can release the brake.

When the pilot control is off, the valve is in zero


position. The flow of pilot pressure oil to the control block and to the slewing pump is then interrupted. In this case, the pilot-control circuit at port
A1 is connected to port L from where the oil returns pressureless to the reservoir.
After activation of the pilot control, the solenoid
displaces the control piston which lets pilot-control
pressure oil flow to the porportional valves on the
control block and to the slewing pump.
Valve Y113 is equipped with an emergency control device permitting the adjustment of the control
piston in the event of system failure.
Pressure switch S113.4 monitors the pressure
build-up on actuation of a working function and
the pressure drop after deactivation of the pilot
control.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 69

Solenoid valve Y290 for pilot-control activation and deactivation


64 S290
61
63

64 S113.4

60

Y242
Y241

Y63 Y290
Y35
Y113
Y10

Fig. 4

Description
Valve Y290 is used for switching the pilot-control
pressure to the proportional valves of the travel
function.

Pressure switch S 290 monitors the pressure


build-up on actuation of a travel function and the
pressure drop after travelling.

When the travel pedal is not depressed, the spolenoid valve is in zero position and the proportional valves ensuring displacement of the spool
are without pilot-control pressure. In this case,
pressure switch S290 is closed.

The solenoid valve can be opened with the mechanical emergency device to permit travelling in
the event malfunctions.

After selecting the travel direction and depressing


the travel pedal, the solenoid is energized and
pilot pressure oil flows to a proportional valve on
the control block. Pressure switch S290 is opened
in the process.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 70

HYDRAULICS

WX210 - WX240

Solenoid valve Y63 for POWER BOOST and power assist functions
64 S290
61
63

64 S113.4

60

Y242
Y241

Y63 Y290
Y35
Y113
Y10

Fig. 5

Description
Solenoid valve Y63 ensures the power assist and
the POWER BOOST functions. The valve is energized when the power assist or POWER BOOST
function is activated.

In zero position of the valve, the sequence stages


of the primary valves are pressure-relieved towards the tank and the pump pressure is limited by
the primary valves to the normal value.

The valves switches pilot pressure to the sequence


stages of both primary valves so that the pump
pressure can rise above the normal value.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 71

5 - 72

HYDRAULICS

WX210 - WX240

Solenoid valve unit Y241 and Y242 for


pump control
P Pilot-control pressure
241, 242 load-sensing pressure to pump regulator
L Tank connection. pressureless
1 Valve housing
2 Solenoid
3 Plunger
4 Control piston
5 Spring plate
6 Compensator spring
7 Emergency control
Fig. 6

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 73

Description

Emergency control

The solenoid valve unit consists of two proportional


valves Y241 and Y242. The valves are assigned to
the pump regulators of the A 8 VO.

By means of the emergency control device, the


control piston can be mechanically adjusted to
supply the pump regulators with load-sensing
pressure in the event of an electronic failure.

The valves are part of the pump control and their


function is to proportionally convert the electrical
signal from the pilot control into a hydraulic control
pressure, the load-sensing pressure.
The valve housing (1) consists of solenoid (2),
plunger (3) and control piston (4) with spring plate
(5) and compensator spring (6).
When a function is activated, the ESX energizes
the solenoid which by magnetic force displaces the
plunger and the control piston against the force of
the compensator spring.
The control edge of the control piston opens a
cross-section through which the pilot pressure can
partly pass to port 241 or 242 as load-sensing
pressure.
The load-sensing pressure builds up a springassisted resetting force which displaces the control
piston backwards against the magnetic force of the
solenoid
The flow cross-section at the control edge of the
control piston is open as long as the magnetic
force is higher. During this time, pilot pressure oil
flows to the pump regulators as load-sensing pressure. The load-sensing pressure increases so that
the resetting forces become stronger. The control
edge is closed when the forces are in equilibrium.
When the solenoid receives less current from the
ESX, the resetting forces press the control piston
into a position creating a drainage cross-section
towards the tank. Through this opening, the loadsensing pressure is reduced. The drainage crosssection closes after the equilibrium of forces has
been reestablished.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 74

HYDRAULICS

WX210 - WX240

TRAVEL CIRCUIT OF 20 KM/H VERSION

40000546-de

Travel circuit 20 km/h, schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 75

Description

Start of the travel function

The travel circuit is equipped of an Inching function


providing the maximum speed pre-selection
through a potentiometer. The potentiometer limits
the regulation rage of the pedal accelerator pedal.
Thus the travel speed can be limited, even if the
accelerator is pressed full stroke.

The selection of the travel direction and the


smooth actuation of the travel pedal are identified
by the ESX causing the opening of virtual bulb
DSF, before the travel movement occurs. In this
manner, the ESX inserts solenoid valve Y290 in
pilot system group (60) and the piloting pressure
reaches, through the inlet filter, into port PV and
proportional valves Y201a and Y201b. Also, the
ESX energises proportional valve Y241, through
which the demand pressure reaches the regulator
of pump 1 through connection X1.

Also, a pressure balance valve is installed in the


travel circuit, forwarding oil to the hydraulic motor
independently from the load pressure, through the
controlling control valve. In this manner a travel
speed independent form the load pressure is provided.
Travelling on a slope is controlled by the hydrostatic brake through a brake valve (102) on the
hydraulic motor.
The travel circuit is powered by oil from pump 1
only. The oil entering the control valve involves the
pressure measuring point, sensor b211 (58) and
the primary valve.

Neutral position
When the travel spool is in neutral position, cooling
oil from pump 1 flows through duct P1 toward the
pressure balance valve and through duct P01,
going around the travel control valve toward duct
C1 and continues through the other spools, eventually reaching the tank duct.
The circulation pressure produced by the pressure
pre-loaded valves in the tank duct is available for
the hydraulic motor through the additional supply
valves (3 + 4) to prevent cavitation.
The piloting pressure is available on undercarriage
control valve (105) where it forwards the delivery to
parking brake solenoid valves Y16, locking swing
axle Y62 and engaging reduced speed Y21.2.

Before travelling
After disengaging the parking brake, the speed is
shifted, set on solenoid valve y21.4. Bulb S16.1
opens and the control indicator light of the parking
brake goes OFF. When voltage is applied to solenoid valve Y62, the pressure of the pilot system
unlocks swing axle cylinders (111). The travel motor is in position Vgmin, when solenoid valve is not
energised. The travel motor can regulate as a function of the high pressure.

Forward travel
Proportional valve Y201a is energised by the ESX
as a function of the travel of the pedal. Valve
Y201a lets piloting pressure enter the upper cavity
of the control valve. This pressure moves the travel
spool downward against the springs. With this
operation, duct C1 is blocked by the piloting edge
thus incrementing the pressure. Beyond 15 bar,
the pressure balance valve opens and the oil is
available on the section of the control valve powering the hydraulic motor through connection A1.
The oil supply to the hydraulic motor, independent
from the load pressure, is dealt with in the paragraph dedicated to the pressure balance valve.
The load pressure, generated during travelling,
passing through the cross and central hole of the
spool toward duct PLS of the load pressure, involves pressure sensor B10.
The output signal from sensor B10 and the rpm
signal from sensor B7 on transmission (101) are
processed by the ESX for the automatic shifting of
the transmission. The oil returning from the travel
motor must flow to the tank, crossing the braking
valve and the rotor the finally flows to the discharge.

Reverse travel
During the reverse phase, proportional valve
Y201b operates, moving the control valve upward.
The pilot edge closed duct P01 and the pump
pressure exceeds 15 bar, thus the pressure balance valve opens, connecting with the control
valve.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 76

HYDRAULICS

WX210 - WX240

Pressure compensator for travel circuit


Function
The function of the pressure compensator is to maintain the discharge flow to the hydraulic motor as determined by the cross-section of the control spool even under varying load pressures. The compensator is represented in the figures in its three states of operation.

Pump 1

Pressure compensator

Stroke 8 mm

Pressureless state

Orifice

Control piston

Spring 15 bar
Charge pressure

PZ-channel

Fig. 1

Operation
After engine start, pump 1 supplies oil to the inlet channel of the pressure compensator.
During activation of a function, the pump 1 generates a pressure of >15 bars. This pressure is admitted
through the transverse bore and the orifice and builds up behind the piston. The force FP moves the piston
against the spring whereby the non-return function of the piston is disabled. The oil from pump 1 flows into
the P channel and to the control spool whose control edge is still closed.
Pressure compensator

Pump 1

Activation of a function

FP

FF

Non-return valve
open
PZ-channel

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Pressure compensator

5 - 77

Pump 1

Regulation

Regulating
edge

FP

FF + FLS

Pressure in channel PZ
FF
FLS
FP

Spring force
Force of the load pressure
Force of the pressure in
channel PZ

Control edge of
the control spool
Charge pressure

Hydraulic motor

Fig. 3

Travel forward or backward


When the control spool is activated, the control
edge is opened. The opening cross-section of the
egde determines the discharge flow to the hydraulic motor and thus its moving speed. On account
of the hydraulic resistance in the hydraulic motor,
a load pressure is generated.
Between the regulating edge of the compensator
and the control edge of the control spool, i.e. in
the PZ channel, the pressure rises. This pressure
rise equally causes the force FP acting on the
piston to increase.
At the same time, the load pressure of the hydraulic motor is available in the spring cavity of the
pressure compensator.
By the forces acting from both sides, the piston is
positioned in such a way that the resulting flow
cross-section at the regulating edge is such that a
pressure build-up occurs in channel PZ.

By means of the control edge, this pressure in


channel PZ generates a pressure differential with
respect to the load pressure in the hydraulic motor.
The compensator keeps this pressure differential
constant as long as the control spool is not moved
to another position.
To each change of the load pressure, the piston
responds briefly by changing the cross section at
the regulating edge until the forces acting on the
piston are again in equilibrium. The pressure differential before and behind the control spool edge
is thus kept constant.
The discharge flow to the hydraulic motor is therefore indepedent of the load pressure. The result is
that even under varying load conditions the
hydraulic motor always moves at the same speed.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 78

HYDRAULICS

WX210 - WX240

Travel control spool


Travel direction

T
PZ

B1

P02

P2

C2

M
PLS

C1

2
P1
P01

A1

A1.1
3

Fig. 1

No.
P1
P01
C1
P2
P02
C2
PZ
T

Description
Pressure channel of pump 1
Pressure channel of pump 1
Duct to the support control valve
Pressure channel of pump 2
Pressure channel of pump 2
Connection to the tank duct
Pressure regulated by the pressure
balance valve
Duct to the tank

No.
A1
A1.1
B1
PLS
M
1
2
3
4

Description
Forward travel
RV only with 25+30 km/h versions
Reverse travel
Load pressure duct
Load-pressure tap for sensor B10
Pressure balance valve
Plug
Replenishing valve, forwards
Replenishing valve, reverse

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WX210 - WX240

HYDRAULICS

5 - 79

Hydraulic and electric rotor (Nos. 75 and 76)

40000547-en

Description
The hydraulic rotor is the rotary connection between superstructure and undercarriage. It consists of an inner and an outer part fully rotatable
with respect to one another. The lines of the superstructure are connected at right angles to ports
around the circumference of the head of the inner
part. Vertical bores of varying length, which end in
horizontal bores, ensures the connection with the
ring ducts of the outer part of the rotor. The ring
ducts are distributed over the height of the outer
part and connected to perpendicular bores leading
to ports on the outside. The lines supplying the
undercarriage components are connected to
these ports.

16
1

The rotor comprises 10 ducts supplying the following functions:

Forward travel
Reverse travel
Stabilizers down
Stabilizers up
Rear axle brake circuit
Front axle brake circuit
Steering to the left
Steering to the right
Pilot-control pressure
Leakage oil / return flow

Duct 1
Duct 2
Duct 3
Duct 4

Duct 5
Duct 6
Duct 7
Duct 8
Duct 9
Duct 10

The electric rotor is the rotary connection between


superstructure and undercarriage. Its inner part,
the stator, is attached with screws to the outer
part of the hydraulic rotor. The stator is equipped
with the contact brushes to which the cables of
the axially arranged harness in the center bore
are connected.
The outer part of the electric rotor is rotatable with
respect to the stator and attached to the superstructure. The base-plate of the outer part carries
the slip-rings arranged one above the other with
the cables from the superstructure connected
radially to the outer part.
The electric rotor has 16 slip-rings numbered in
rising order from bottom to top for the functions
shown in the table opposite:

10

Fig. 1

Slip-ring 1
Slip-ring 2
Slip-ring 3
Slip-ring 4
Slip-ring 5
Slip-ring 6
Slip-ring 7
Slip-ring 8
Slip-ring 9
Slip-ring 10
Slip-ring 11
Slip-ring 12
Slip-ring 13
Slip-ring 14
Slip-ring 15
Slip-ring 16

Parking brake pressure switch


Creep speed
Speed sensor output 1
Speed sensor output 2
Sensor power supply
1st gear
Floating-axle blocking
Parking brake
Outrigger individual control
Outrigger individual control
Outrigger individual control
Outrigger individual control
Not used
Not used
Ground
Ground

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 80

HYDRAULICS

WX210 - WX240

Travel drive (Nos. 100, 101 and 102)

40000378-en

3
1

Fig. 1

No.
1
2
3
4

Description
Rigid axle, No. 100
Multi-disk speed-change gearbox No. 101
Speed sensor B7
Travel oil motor, No. 102

Description
The rigid axle is designed as an external planetarywheel driving axle with integrated immersed multidisk brakes. The multi-disk speed-change gearbox
is a single-stage planetary gear with two speeds
and a neutral position. Gear-shifting is effected by
two multi-disk clutches.
The hollow wheel of the planetary stage is braked
for the 1st gear and released for the 2nd gear. The
multi-disk clutches are controlled by pilot pressure
via a solenoid valve. Solenoid valve Y 21.4 supplies oil to one of the clutches so that one of the
two gears is always engaged, except in case the
parking brake is applied. In this case, both clutches
are pressureless and the multi-disk speed-change
gearbox performs the parking brake function.

The speed sensor provides the electronics with a


speed signal and a sense-of-rotation signal.
For towing purposes, the travel drive has a neutral
position in which the axle is disconnected from the
travel oil motor. The neutral position is engaged
mechanically by turning an eccentric. A gearwheel
in the gearbox is axially shifted so that the interlock
between two gearwheels is interrupted.
The travel oil motor is fastened with an adaptor
ring to the multi-disk speed-change gearbox.

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WX210 - WX240

HYDRAULICS

5 - 81

Travel oil motor type A 6 VM (20 km/h) (No. 102)

G1

MA

SV
M1

Gext

9
8
6

Fig. 1

No.
1
2
3
4
5
6
7
8
9
A

Description
Drive shaft with bearings
Cylinder block with axial pistons
Angle plate
Porting pintle
Spring
Vgmin stop setscrew
Vgmax stop setscrew
Stroke control
Travel brake valve
Connection for reverse travel

No.
B
X
M1
MA
MB
G1
Gext
T
SV

Description
Connection for forward travel
Connection for creep speed
Measuring port for control chamber
pressure
Measuring port
Measuring port
Measuring port, travel pressure
Closed
Leakage oil port
Secondary valve (2 units)

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5 - 82

HYDRAULICS

WX210 - WX240

Travel oil motor, regulator (No. 102)

6
5
4
3
2
1
Fig. 1

No.
1
2
3
4
5
6
RF
KF

Description
Adjusting piston
Spring
Compensator spring
Spring plate
Control piston
Setscrew for regulation start
Rod side of adjusting piston
Piston side of adjusting piston

RF

KF

Fig. 2

Description
The travel oil motor is an axial piston motor in
bent-axis design with variable displacement.
The angle of the axial-piston unit can be varied by
a regulator as a function of high pressure.

Automatic regulation
In neutral position and during travelling in the lowpressure range, the piston unit (2) is in the Vgmin
position. The angle plate (3) is in contact with the
Vgmin setscrew (6). The hydraulic power supplied
in the form of discharge flow and pressure is converted by the short-stroking axial pistons to high
output speed at low torque. The pressure built up
during travelling is admitted to the rod side of the
adjusting piston and to the metering side at the
control piston of the regulator. The hydraulic force
at the adjusting piston keeps the unit at the Vgmin
limit stop. The hydraulic force at the metering side
of the control piston acts against the spring under
the control piston. The spring force is adjustable
and determines the regulation start of the travel
motor.

With increasing travelling resistance, the high


pressure rises until regulation start is reached.
The high pressure displaces the control piston
with its control edge so that the high pressure
reaches the large surface of the adjusting piston.
The adjusting force tilts the cylinder block (2) to a
greater angle so that the stroke of the axial pistons increases. The output torque of the oil motor
increases whereas the output speed diminishes.
The machine travels with greater traction and
lower speed. The position of the piston unit is
continuously varied with the high pressure until
the end of the regulation range is reached.
The end of the regulation range is reached when
the piston unit with the angle plate runs into the
Vgmax stop (7).
When the travelling resistance has been overcome, the high pressure decreases and the control piston is set back by spring force. The pressure under the adjusting piston escapes towards
the housing and the piston unit (2) is tilted towards
Vgmin. The output speed increases and the output torque diminishes.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 83

6
5
4
3
2

SV

1
Fig. 3

No.
1
2
3
4
5
6
RF
KF
SV

Description
Adjusting piston
Spring
Compensator spring
Spring plate
Control piston
Setscrew for regulation start
Rod side of adjusting piston
Piston side of adjusting piston
Secondary valve (2 units)

RF

KF

Fig. 4

Creep speed
The automatic regulation process is overridden by the creep speed function.
This function permits slow travelling with maximum traction force.
Solenoid valve Y21.2 directs pilot pressure to port X of the adjusting unit (8).
The control piston (5) is displaced against the compensator spring (3). The control edge opens and pressure
is admitted to the piston side under the adjusting piston (1). The force of the adjusting piston swivels the
piston unit against the Vgmax setscrew (7).

Secondary relief
Inadmissibly high pressures are safely prevented by secondary valves. Both travel directions are provided
with one valve each. Besides the relief function, the valves are also equipped with replenishing non-return
valves.
Travel oil motor (20 km/h) with travel brake valve

Fig. 5

Fig. 6

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5 - 84

HYDRAULICS

WX210 - WX240

Travel oil motor, travel brake valve (No. 102)


4

2
1

B1

B
3

A1

3
Fig. 1

No.
1
2
3
4
5
A
A1
B1
S

Fig. 2

Description
Travel brake valve housing
Travel brake piston
Non-return and replenishing valves
Secondary valves
Cold starting valve with 80 bar spring
Oil flow from the control valve
Travel pressure to oil motor
Return from oil motor
Closed

Service brake valve symbol

Fig. 3

Description
The travel brake valve is flange-mounted on the
travel oil motor. It works as an automatic restrictor
valve protecting the travel oil motor in both directions of rotation against inadmissibly high speeds.
In the pressureless state, the braking piston (2) is
held by spring force in its zero position. The oil
motor is supported on both sides by the closed
braking piston.
The travel pressure, in the example, flow to connection A and from here into the service brake
valve and through the check valve, directly to the
hydraulic motor, connection A1. The pressure reaches also, through a diaphragm and a cold starting
valve, with an 80 bar spring, the brake piston and
moves it. On the opposite side, the oil is rejected in
a controlled manner by diaphragms and a check
valve, so that the brake valve piston is moved.
The pressure level existing during driving on level
ground is sufficient to open the braking piston
against the adjusting spring to such an extent that
the return oil from port B1 of the oil motor can flow

unrestricted past the braking piston (2) via a nonreturn valve (3) to port B.
When the pressure drops, the adjusting spring
displaces the braking piston so that the return
cross section is reduced and the returning oil flow
is restricted.
In this manner, the rpm of the hydraulic motor and
the speed of the machine are controlled on rough
terrain.
Additional suction valves (3) protect the travel motor on both sides against a lack of oil, i.e. in case of
leakages causing sliding on a slope. The pre-load
pressure from the duct of the control valve block,
through the additional suction valves in the control
valve block, the undercarriage and through additional suction valve (3) in the service brake valve,
finally reaches the hydraulic motor.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 85

5 - 86

HYDRAULICS

WX210 - WX240

Undercarriage control block (Nos. 104, 105 and 106)


105

106

104

4
3
1
2
Fig. 1

No.
104
105
106
1
2
3
4

Description
Valve housing
Diaphragm accumulator
Pressure switch S 16.1
Solenoid valve Y16
Solenoid valve Y21.4
Solenoid valve Y62
Solenoid valve Y21.2

for parking brake pilot lamp


for parking brake with emergency release
for 1st/2nd gear
for floating-axle support
for creep-speed gear

Symbol
Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 87

Description
The control block is located in the undercarriage
frame above the multi-disk clutch. Shifting functions are performed by pilot pressure. The block is
also connected to a reservoir line.
The valve housing (1) is equipped with four solenoid valves, pressure switch 106 and diaphragm
accumulator 104.
Solenoid valve Y16 (1) actuates the parking
brake.

The parking brake function is ensured by means of


the multi-disk clutches in the speed-change gearbox. When both clutches are without pressure, the
parking brake function is ensured by the multi-disk
speed-change gearbox.
In the deenergized state, the control piston of Y16
is connected to the reservoir. A gear engaged beforehand and the respective clutch are switched
without pressure. The switching pressure in the
clutch escapes together with the accumulator
pressure through the outlet restrictor into the reservoir line.
When the parking brake is released, the solenoid is
energized and the control piston supplies pilot
pressure for switching to a clutch of the speedchange gear. The accumulator is loaded and pressure switch S 16.1 opens its switching contact so
that the pilot lamp of the parking brake goes out.
The corresponding multi-disk clutch opens and
cancels the parking brake function of the speedchange gearbox.
An emergency release circuit on the solenoid side
can be used in the event of electrical supply failure
to shift the control piston mechanically in such a
way that the pilot pressure can release a multi-disk
clutch.

Solenoid valve Y21.4 (2) operates the gearshift


function.

When the parking brake is released, the valve always directs pilot pressure to one of the two multidisk clutches. Which of the clutches is pressurized
depends on whether the solenoid is on or off.
When the solenoid is off, pilot pressure is admitted
to the clutch for 2nd forward gear. When it is on,
pilot pressure is admitted to the clutch for the 1st
gear.
Solenoid valve Y62 (3) is used for applying and
releasing the floating-axle blocking.

Without current in the solenoid, the floating axle is


blocked since the valves integrated in the cylinders
are without pressure. When the solenoid is energized, the control piston is shifted so that the the
blocking valves in the cylinders are unblocked by
the pilot pressure.
Solenoid valve Y21.2 (4) is used to engage the
creep-speed gear of the travel oil motor.

When the creep-speed gear is engaged, the solenoid is energized and the control piston sends pilot
pressure to the regulator of the travel oil motor.
The control piston in the regulator is displaced and
the travel high pressure acts on the adjusting piston with the drive unit swivelling to the Vgmax position. The travel oil motor has then maximum. displacement volume and the machine moves at
creep speed.
Pressure switch S16.1 (106) performs two functions: it monitors the shifting pressure and controls
the parking brake pilot lamp. If the pressure drops
below 30 bars, the switch contact closes and the
travel direction is set to neutral. The parking brake
pilot lamp lights up, too.
Pressure accumulator (104) has the purpose of
smoothing the effect of the parking brake in the
event the same is activated during travelling or in
case of electrical malfunctions.

The energy accumulated slows down, through the


1-mm orifice, the pressure discharge into the
blades of the clutches actuated. The braking effect
is applied smoothly.

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5 - 88

HYDRAULICS

WX210 - WX240

Steered floating axle (No. 110)

Fig. 1

Description
The steered axle is designed as a wheel-hub
planetary gear drive axle with oil-immersed integrated multi-disk brakes. The steering knuckles are
moved via steering rods by the steering cylinder in
the axle body. The steered axle is a floating axle
suspended in the undercarriage frame. The free
floating movement of the axle which is necessary
for driving must be blocked during the work with
the floating-axle cylinder.

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WX210 - WX240

HYDRAULICS

5 - 89

Floating-axle cylinder (No. 111)


Check valve

Check valve detail

Preloading pressure
Control piston

Fig. 1

Description
The floating-axle cylinders are single-action cylinders with integrated check valves connected by a
line to which the supply line is connected which
serves also as the control line.
The cylinder pistons rest on the pressure pads of
the steered axle. To improve the driving stability,
especially in fast driven bends, the ports of both
cylinders are equipped with restrictor non-return
valves restricting the oil flow leaving the cylinder.
On the other hand, the oil flowing into the cylinder
can fill the cylinder through the non-return valve
without being restricted.
When the machine is driven off-road with the check
valves being open, the axle floats depending on
the terrain contours. The movement of the axle
presses the piston into one of the floating cylinders. The oil volume thus displaced flows to the
opposite cylinder and extends the piston of the
latter. When the check valves are closed, the oil
volume is entrapped in both cylinders and the floating axle blocked.

Without control pressure, the check valve is closed


by the force of the spring, possibly assisted by the
internal cylinder pressure. When the floating-axle
blocking is released, the check valves are opened
by pilot pressure supplied to the valves via solenoid valve Y62. With the valves open, the pilot
pressure acts as preloading pressure on the pistons which are pressed by hydraulic force on the
pressure pads of the axle.
Restrictor non-return valves

Fig. 2

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5 - 90

HYDRAULICS

WX210 - WX240

TRAVEL CIRCUIT OF 25 AND 30 KM/H VERSIONS


Travel circuit 25 and 30 km/h, schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000548-en

WX210 - WX240

HYDRAULICS

5 - 91

Description
The travel circuit is equipped of an Inching function
providing the maximum speed pre-selection
through a potentiometer. The potentiometer limits
the regulation rage of the pedal accelerator pedal.
Thus the travel speed can be limited, even if the
accelerator is pressed full stroke.
Also, a pressure balance valve is installed in the
travel circuit, forwarding oil to the hydraulic motor
independently from the load pressure, through the
controlling control valve. In this manner a travel
speed independent form the load pressure is provided.
Additional supply device (14) provides the filling of
the travel motor.
Travelling on a slope is controlled by the hydrostatic brake through a brake valve (102) on the
hydraulic motor.
The travel circuit is powered by oil from pump 1
only. The oil entering the control valve involves the
pressure measuring point, sensor B211 (58) and
the primary valve.

Neutral position
When the travel spool is in neutral position, cooling
oil from pump 1 flows through duct P1 toward the
pressure balance valve and through duct P01,
going around the travel control valve toward duct
C1 and continues through the other spools, eventually reaching the tank duct.
The circulation pressure produced by the pressure
pre-loaded valves in the tank duct is available for
the hydraulic motor through the additional supply
valves (3 + 4) to prevent cavitation.
The piloting pressure is available on undercarriage
control valve (105) where it forwards the delivery to
parking brake solenoid valves Y16, locking swing
axle Y62 and engaging reduced speed Y21.2.

Prior to travelling
After disengaging the parking brake, the speed is
shifted, set on solenoid valve y21.4. Bulb S16.1
opens and the control indicator light of the parking
brake goes OFF. When voltage is applied to solenoid valve Y62, the pressure of the pilot system
unlocks swing axle cylinders (111). The travel motor is in position Vgmin, when solenoid valve is not
energised. The travel motor can regulate as a function of the high pressure.

Start of the travel function


The selection of the travel direction and the smooth
actuation of the travel pedal are identified by the
ESX causing the opening of virtual bulb DSF, before the travel movement occurs. In this manner,
the ESX inserts solenoid valve Y290 in pilot system group (60) and the piloting pressure reaches,
through the inlet filter, into port PV and proportional
valves Y201a and Y201b.

Also, the ESX energises proportional valve Y241,


through which the demand pressure reaches the
regulator of pump 1 through connection X1.

Forward speed
Proportional valve Y201a is energised by the ESX
as a function of the travel of the pedal. Valve
Y201a lets piloting pressure enter the upper cavity
of the control valve. This pressure moves the travel
spool downward against the springs. With this
operation, duct C1 is blocked by the piloting edge
thus incrementing the pressure. Beyond 15 bar,
the pressure balance valve opens and the oil is
available on the section of the control valve powering the hydraulic motor through connection A1.
The oil supply to the hydraulic motor, independent
from the load pressure, is dealt with in the paragraph dedicated to the pressure balance valve.
The load pressure, generated during travelling,
passing through the cross and central hole of the
spool toward duct PLS of the load pressure, involves pressure sensor B10.
The output signal from sensor B10 and the rpm
signal from sensor B7 on transmission (101) are
processed by the ESX for the automatic shifting of
the transmission. The oil returning from the travel
motor must flow to the tank, crossing the braking
valve and the rotor the finally flows to the discharge.

Additional supply in forward travel


The additional supply provides the filling of the
hydraulic motor at high speed. Additional supply
device (14) is automatically activated, in second
forward, by electronic controller A100. Oil under
pressure from the fan circuit is used to power the
additional supply device. The pressure relief valve
reduces the pressure on the fan to the value of the
additional supply pressure available on connection
A1.1 of the control block, arriving through a check
valve in the forward travel line. Should the pressure drop below the additional supply one, i.e.
downhill, the check valve in connection A1.1 opens
and the hydraulic motor gets the additional supply
pressure. Once the travel pressure increases, the
check valve closes.

Reverse
During the reverse phase, proportional valve
Y201b operates, letting the piloting pressure flow
through, proportionally to the pedal travel, into the
lower piloting chamber and moves the travel control valve upward against the force of the spring.
Oil from pump 1 now flows from the pump duct to
the control block, connection B1 and through the
rotor, into the hydraulic motor.

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5 - 92

HYDRAULICS

WX210 - WX240

Travel control spool


Travel direction

T
PZ

B1

P02

P2

C2

M
PLS

C1

2
P1
P01

A1

A1.1
3

Fig. 1

No.
P1
P01
C1
P2
P02
C2
PZ
T

Description
Pressure channel of pump 1
Pressure channel of pump 1
Duct to the support control valve
Pressure channel of pump 2
Pressure channel of pump 2
Connection to the tank duct
Pressure regulated by the pressure
balance valve
Duct to the tank

No.
A1
A1.1
B1
PLS
M
1
2
3
4

Description
Forward travel
RV only with 25+30 km/h versions
Reverse travel
Load pressure duct
Load-pressure tap for sensor B10
Pressure balance valve
Plug
Replenishing valve, forwards
Replenishing valve, reverse

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WX210 - WX240

HYDRAULICS

5 - 93

Replenishing system (Nos. 13 and 14)

Fig. 1

Description
The replenishing system prevents cavitation in the
travel oil motor, especially during downhill drives.
Valve housing (1) accomodates solenoid valve Y295
and pressure-reducing valve (3). The replenishing
system is fed via line (5) with pressure from the fan
circuit (4). During forward travel in 2nd gear, the CU
activates solenoid valve Y295 and the fan pressure
reaches pressure-reducing valve (3). The adjustable
outlet pressure of valve (3) is admitted as replenishing pressure via line (6) to port A1.1 of the control block in which non-return valve (7) is located.

No.
1
2
3
4
5
6
7
8

Description
Valve housing
Solenoid valve Y295
Pressure-reducing valve
Fan pressure line
Fan pressure branch-off
Replenishing pressure line
Non-return valve in port A1.1
Leakage-oil line

When the travel pressure drops below the replenishing pressure during downhill drives, non-return
valve (7) opens and the travel oil motor receives
additional pressure oil.
When the travel pressure increases again, nonreturn valve (7) is closed to the replenishing pressure.
During reverse travel and driving in 1st gear, the
replenishing system is off.

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5 - 94

HYDRAULICS

WX210 - WX240

Travel oil motor type A6VM for 25/30 km/h, (No. 102)

40000386-en

Symbol

Fig. 1

No.
1
2
3
4
5
M3
M2

Description
Adjusting device, regulator
Hydraulic 'Vgz' adjustment
Travel brake valve
Secondary valve, 2 units
Flushing restrictor
Measuring point for regulation start
Measuring point for 'Vgz' adjustment

Fig. 2

Description

Downhill

The travel oil motor for machines with a travelling


speed of 25 km/h and 30 km/h is set to a lower
displacement volume in order to achieve higher
motor speeds.

During downhill drives in 2nd gear, the travel oil


motor is at first in its 'Vgmin' position. Due to the
low output torque, the braking pressure between
oil motor and braking piston of the travel brake
valve is high. When the braking pressure reaches
the switching pressure of the 'Vgz' adjustment, the
switching piston is being displaced against the
spring and braking pressure gets under the adjusting piston.

As a protection against inadmissibly high speeds


during downhill drives and to improve the braking
action, the travel oil motor is equipped with a supplementary hydraulic adjusting device (2). The socalled 'Vgz' adjustment is composed of a springloaded switching piston pressurizing an adjusting
piston below the regulator piston.
The adjusting function (2) works only during forward travel in 2nd gear. Port B is the pressure side
for forward travel. The return oil from the oil motor
must flow as braking pressure past the travel brake
valve piston to port A. Port A receives pressure for
reverse travel.

The adjusting piston raises the regulator piston


with the motor being set to an angle approximately
in the middle of the adjusting range.
The increase of the angle results in a higher speed
of the oil motor. The output torque increases
whereby the braking pressure is reduced.
The 'Vgz' adjustment is ineffective in the 1st gear.
The switching pressure engageing the clutch for
the 2nd gear acts also on the switching piston of the
'Vgz' adjustment.
The travel motor is additionally equipped with a
flushing restrictor (5) for temperature limiting.
The restrictor lets the return oil flow into the motor
housing and from there through the leakage-oil line
to the tank.

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WX210 - WX240

HYDRAULICS

5 - 95

Travel oil motor (25 and 30 km/h) with disconnectable hydraulic 'Vgz'
adjustment (No. 102)

40000387-en

Changing speed
solenoid valve

Pressure side for


forward travel

Disconnection pressure
with 1st speed selected

Fig. 1

Description
'Vgz' adjustment designates an intermediate position inside the oil motor adjusting range. The adjustment is purely hydraulic and works only during
forward travel.
During reverse travel, the 'Vgz' adjustment is on
the pressure side of the oil motor. With high travel
pressure, the high-pressure-dependent regulation
would respond earlier and thus override the 'Vgz'
adjustment.
The 'Vgz' adjustment protects the travel oil motor
against inadmissibly high motor speeds, especially
during downhill drives where the weight of the machine drives the travel oil motor via the drivetrain.
The 'Vgz' adjustment is off in 1st gear with the
switching pressure of the 2nd gear clutch acting on
the control piston of the 'Vgz' adjustment via port
X2. The cylinder of the adjustment is then depressurized towards the T2 port of the oil motor.

In 2nd gear there is no cut-off pressure from first


speed, of travel Vgz, thus travel Vgz is ready to
operate. The pressure between the oil motor and
the travel brake valve piston acts as braking pressure on the control piston which is pushed against
the spring of the 'Vgz' adjustment.
During downhill drives with high speed, a high
braking pressure is generated which adjusts the
control piston in such a way that the braking pressure becomes the adjusting pressure under the
piston side of the adjusting device. The travel oil
motor is set to a greater angle whereby the braking
pressure drops. On long slopes, the braking pressure is balanced with the spring force of the control
piston permitting a pressure build-up below the
adjusting piston which moves the oil motor drive
unit approximately into the center of its adjusting
range. The travel speed and especially the speed
of the oil motor are thus effectively limited.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 96

HYDRAULICS

WX210 - WX240

Travel oil motor, travel brake valve (No. 102)


4

2
1

B1

B
3

A1

Fig. 2

Fig. 1

No.
1
2
3
4
5
A
A1
B1
S

Description
Travel brake valve housing
Travel brake piston
Non-return and replenishing valves
Secondary valves
Cold starting valve with 80 bar spring
Oil flow from the control valve
Travel pressure to oil motor
Return from oil motor
Closed

Service brake valve symbol

Fig. 3

Description
The travel brake valve is flange-mounted on the
travel oil motor. It works as an automatic restrictor
valve protecting the travel oil motor in both directions of rotation against inadmissibly high speeds.
In the pressureless state, the braking piston (2) is
held by spring force in its zero position. The oil
motor is supported on both sides by the closed
braking piston.
The travel pressure, in the example, flow to connection A and from here into the service brake
valve and through the check valve, directly to the
hydraulic motor, connection A1. The pressure reaches also, through a diaphragm and a cold starting
valve, with an 80 bar spring, the brake piston and
moves it. On the opposite side, the oil is rejected in
a controlled manner by diaphragms and a check
valve, so that the brake valve piston is moved.

unrestricted past the braking piston (2) via a nonreturn valve (3) to port B.
When the pressure drops, the adjusting spring
displaces the braking piston so that the return
cross section is reduced and the returning oil flow
is restricted.
In this manner, the rpm of the hydraulic motor and
the speed of the machine are controlled on rough
terrain.
Additional suction valves (3) protect the travel motor on both sides against a lack of oil, i.e. in case of
leakages causing sliding on a slope. The pre-load
pressure from the duct of the control valve block,
through the additional suction valves in the control
valve block, the undercarriage and through additional suction valve (3) in the service brake valve,
finally reaches the hydraulic motor.

The pressure level existing during driving on level


ground is sufficient to open the braking piston
against the adjusting spring to such an extent that
the return oil from port B1 of the oil motor can flow

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

1st + 2nd Gear - Floating axle

5 - 97

40000514-en

Fig. 23

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 98

HYDRAULICS

WX210 - WX240

BRAKING, STEERING AND FAN CIRCUIT

40000550-de

Schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 99

Braking, steering and fan circuit of the 20 km/h version

45

230
231

46

41

40

S17

44

Fig. 2

The diesel engine drives the gear pump via its


P.T.O. The gear pump can be a single or optionally
a double pump (230). The pump feeds the dualcircuit brake system, the steering system and the
fan drive motor (7) of the combined radiator. Machines with higher travel speed are moreover
equipped with a replenishing system (14) for the
travel oil motor.
In operation, the gear pump supplies its oil at first
to the pedal brake valve (41). Besides the dualcircuit pedal valve, the brake valve also accomodates the accumulator loading device.
After loading of the accumulators, the accumulator
loading valve switches over and the oil flow is directed to priority valve (44).
The priority valve divides the discharge flow into oil
flowing to the steering valve (40) and to the fan
drive (7) with the steering having priority.

In neutral position of the steering valve (40), the LS


line is pressureless and the oil flow is directed by
priotity valve (44) completely to fan drive (7).
The fan motor is driven depending on temperature.
A proportional valve Y131 connected in parallel
with the gear motor determines the amount of oil
used for driving the fan. At low oil temperatures,
the proportional valve is opened wider than at high
oil temperatures. This results in a corresponding
fan speed. The load-limit regulator A10 senses
three temperatures: those of the hydraulic oil, of
the coolant and the charge air temperature. The
load-limit regulator evalutes the different temperature values and controls the proportional valve
Y131 accordingly.
The replenishing system (14) receives the fan input pressure and makes it available as replenishing pressure to the travel oil motor.

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5 - 100

HYDRAULICS

WX210 - WX240

Steering system
Steering valve OSPQ 75/175 LS, No. 40

40000552-en

Description
The steering unit called OSPQ is a load-sensing
steering unit with closed center position and built-in
oil flow amplifier.
In porportion to the turning angle of the steering
wheel and dependent on the amplification factor,
the oil flow is metered past the gearwheel set to
the the left (L) or to the right (R).
The amplified flow is the oil which flows via the
amplifier and which joins the oil flow from the
gearwheel set delivered via the metering orifice.
At steering-wheel turning speeds of less than
10 rpm there is no oil flow amplification. At faster
steering speeds, the oil flow amplification joins in
and is fully effective for steering-wheel turning
speeds of >20 rpm.

Fig. 1

The amplification factor is 2.5. This means that at


steering-wheel turning speeds of >20 rpm, the
amount of oil flowing past the gearwheel set into
the steering cylinder is 2.5 times as high as the
normal flow.

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WX210 - WX240

HYDRAULICS

5 - 101

Neutral
In neutral position, the control spool is closed and
the LS line depressurized towards the reservoir.

Steering to the left (example)


When the steering wheel is turned slowly, the amplifier and the control spool are displaced in the
direction of the arrow. The oil flows through the
amplifier and the metering orifice to the gearwheel
set and further via port L to the steering cylinder.

Fig. 2

The volume flow to the steering cylinder is determined by the metering orifice. The steering pressure building up behind the metering orifice is admitted to the LS channel and closes the non-return
valve. The LS pressure generated by priority valve
(44) in the attached LS line influences the opening
cross-section at the control spool in such a way
that the pressure differential at the metering orifice
is maintained.
The remaining oil flows to the fan circuit.
At faster steering speeds, the pressure drop
caused by the metering orifice activates the amplifier piston to amplify the oil flow.
The max. steering pressure is limited by the built-in
pressure-limiting valve in the LS channel of the
steering unit. The steering cylinder and the lines
are protected by shock valves. Oil replenishment is
ensured by non-return valves preventing cavitation
in the steering system.

Emergency steering capability


The steering unit is equipped with a non-return
valve permitting manual steering in the event of oil
supply failure.

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 102

HYDRAULICS

WX210 - WX240

Priority valve (Nos. 44)

Fig. 6

Fig. 4

Description
Symbol
P
7 bar

LS

The priority valve is used in conjunction with steering valves in closed-center load-sensing design.
The valve divides the discharge flow and directs
the two partial flows to the steering system and the
fan drive with the steering system having priority.
The priority valve works like a three-way flow control valve with the regulated flow (CF) being made
available to the steering system and the remaining
flow (EF) to the fan drive.

Neutral
EF CF
Fig. 5

Pump

CF

Steering (control flow)

EF

Fan drive (excess flow)

LS

Load signal

The discharge flow is admitted to both sides of the


control piston via metering orifices. In neutral position, the load-signal line (LS) is connected via the
non-return valve in the steering valve with the resevoir.
The control spool is displaced against the die 7-bar
spring so that the oil now flows via port EF to the
fan drive.

Steering
During steering, the control piston is positioned by
the regulating forces in such a way that its control
edge maintains a pressure differential via the metering orifice in steering valve (40).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 103

5 - 104

HYDRAULICS

WX210 - WX240

Fan circuit

40000553-en

11

6
7

2
14

12
1

13

Fig. 1

Legend
1. Steering and fan pump
2. Silencer
3. Priority valve
9

4. Lenkventil
5. Fan motor, gearwheel motor
6. Cover with proportional valve Y131

10
Fig. 2

7. Nitrogen accumulator
8. Combibned radiator
9. Proportional valve with pressure limiting
10. Pressure measuring point
11. Hydraulic reservoir
12. Braking pump
13. Brake pedal valve
14. Grab rotation valve

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 105

Combined radiator with controlled fan


drive (No. 7)
Description
The combined radiator comprises three coolers
with the foremost cooler in driving direction being
traversed by the return oil from the working hydraulics, the rearmost one by the coolant from the diesel engine and the uppermost one by the charge
air form the turbocharger. The fan wheel iis driven
by a speed-controlled gearwheel motor. The speed
is controlled dependent on temperature by the
load-limit regulator. At low temperatures, the fan
turns slowly. This means that noise emissions are
kept low and power demands are minimized.
Moreover, the coolant and the hydraulic oil reach
their operating temperature very fast.
The flow of cooling air is sucked by the fan wheel
from the center of the excavator through the combined radiator and discharged to the outside
through the air vents in the hood.
Gear motor (5) receives pressure oil from gear
pump (1) via priority valve (3).
Fan motor (5) is connected to a nitrogen accumulator (7) whose function is to absorb sound waves in
the hydraulic oil.

Lower temperatures result in the load-limit regulator supplying a high current to the proportional
valve. The control piston is opened wide by the
electrical force and creates a by-pass through
which the oil flows past the oil motor to the tank,
causing the fan to turn at a lower speed.
With increasing temperature, the load-limit regulator reduces the current to the proportional valve.
The control piston opens less so that the oil motor
gets a higher amount of oil.
The fan speed increases.
A pressure-limiting valve integrated in proportional
valve (9) protects the fan circuit against pressure
peaks. After engine stop, the oil supply in the oil
motor is ensured during the fan wheel delay by a
replenishing valve until the fan stops.
In the event of defects, e.g. broken cable, the proportional valve is without current and the fan wheel
turns at maximum speed. In this case, the pressure in the fan circuit is limited by the pressurelimiting valve.

The pressure oil is also available in (6) of the oil


motor where proportional valve Y131 (9) is provided as a by-pass.
The load-limit regulator A10 evaluates three temperature signals permanently supplied by coolant
temperature sensor B13.1, charge-air temperature
sensor R10.3 and hydraulic oil temperature sensor
R14. The higher of the three values is used for
controlling proportional valve Y131.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 106

HYDRAULICS

WX210 - WX240

Replenishing system (for 25 and 30 km/h version) (Nos. 13 and 14)

40000554-de

5
1

8
7

Fig. 1

Valve housing

Solenoid valve Y295

Pressure-reducing valve

Fan pressure line

Fan pressure branch-off

Replenishing pressure line

Non-return valve in port A1.1

Leakage-oil line

Replenishing system, description

During forward travel in 2nd gear, the CU activates


solenoid valve Y295 and the fan pressure reaches
pressure-reducing valve (3). The adjustable outlet
pressure of valve (3) is admitted as replenishing
pressure via line (6) to port A1.1 of the control
block in which non-return valve (7) is located.
When the travel pressure drops below the replenishing pressure during downhill drives, non-return
valve (7) opens and the travel oil motor receives
additional pressure oil.
When the travel pressure increases again, nonreturn valve (7) is closed against the replenishing
pressure.

The replenishing system prevents cavitation in the


travel oil motor, especially during downhill drives.

During reverse travel and driving in 1st gear, the


replenishing system is off.

Valve housing (1) accomodates solenoid valve Y295


and pressure-reducing valve (3).

The replenishing system is supplied with pressure


from fan circuit (4) via line (5).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 107

Brake system in superstructure and undercarriage with Nos. 40, 41, 43, 44

40000551-en

Superstructure

43
41

231
43

Fig. 1

Undercarriage
brake circuit 2 of rear axle

brake circuit 1 of front axle

Fig. 2
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 108

HYDRAULICS

Pedal brake valve (No. 41)

WX210 - WX240

When the pressure in the accumulators drops and


when the minimum pressure, i.e. the switch-on
pressure is reached, the accumulators are filled
again and the whole cycle repeats itself.
During braking, two pressure-control valves are
activated by the pedal. These valves permit precision control of the braking pressure at ports F1 and
F2 in proportion to the effort with which the pedal is
depressed and thus the pedal excursion.
When the pedal is at rest, ports F1 and F2 are
without pressure and the braking cylinders are
connected to the reservoir.
When the pedal is depressed forcefully, the pressure rises in proportion to the change of the pedal
angle. When the pedal is depressed to the limit
stop, the braking pressure is limited to the preset
pressure of 60 bars. This pressure limiting is independent of the accumulator pressure.

Travel direction

Both braking circuits are separated from one another by means of protection valves. If one of the
circuits fail, the other remains fully operational.
With the intact circuit, the machine can be braked
in an emergency.

Fig. 3

Fig. 5

The three pressure switches at the underside of


the brake valve have the following functions:
S18
Fig. 4

Stop-light switch,
above 4 bars, the brake light is on.
INFO: after 5 minutes, the stop-light is
switched off by the CU.

The pedal brake valve is a compact unit consisting


of a dual-circuit accumulator loding valve, a dualcircuit brake valve and relief valves.

S18.1 Minimum braking pressure monitor:


above 105 bars, the warning lamp goes
out.

During the loading cycle, a constant oil flow to the


accumulators (43) is ensured by a flow divider.
When the maximum pressure, i.e. the shutoff pressure, is reached in the braking circuit, the oil flow is
stopped and all the oil flows to port S to which the
optional grab rotation valve (231) is connected.

S62.1 Floating-axle blocking,


above a braking pressure of 52 bars, the
floating axle is blocked.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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5 - 109

5 - 110

HYDRAULICS

WX210 - WX240

UNDERCARRIAGE, STABILIZERS
Schematic diagram

Fig. 1
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000340-en

WX210 - WX240

HYDRAULICS

5 - 111

Description

Starting a movement

The stabilizers and their variants enlarge the range


of application of the machines.

After starting the stabilizing function in one direction, the virtual pressure switch DSL opens, before
the movement begins. The ESX activates solenoid
valve Y113 in the pilot-control unit (60) and the
pilot pressure is admitted via the inlet filter in port
PV to proportional valves Y202a and Y202b.

The levelling blade can be used to perform levelling work. The blade is parallel-guided to ensure
that the same cutting angle is maintained independent of blade height.
In stabilized condition, the levelling blade improves
the stability of the machine.
When lowered, the outriggers improve the supporting capabilities and the stability of the machine, for
instance, when heavy loads are being lifted.
The levelling blade and outrigger cylinders are
equipped with integrated and pilot-operated nonreturn twin valves blocking off the piston and rod
sides of the cylinders without producing leakage
oil.

Neutral
Only pump 2 supplies oil to the stabilizers. The oil
is admitted via port P2 into the control block and to
pressure sensor B210, to the pressure measuring
point and to the primary pressure-limiting valve.
In neutral position of the stabilizer control spool,
the flushing oil volume from pump 2 flows past the
control spool into channel C2 and via the tank
channel precharging valves into the return line.
Both working lines A2 and B2 to the stabilizer cylinders are then also connected with the leakage oil
channel via the pressure relief of the control spool.
This pressure-relief function is necessary for perfect closing of the non-return twin valves in the
stabilizer cylinders. Any existing residual pressure
would keep the twin valves open so that the stabilizer cylinders would give in. The stabilized machine might then loose its supporting stability or the
stabilizers, when in raised position, might lower on
their own.

The ESX energizes also proportional valve Y242,


whereby load-sensing pressure is admitted to
pump regulator port X1.

Lowering
During lowering of the stabilizers, proportional
valve Y202b is energized from the ESX whereby
the pilot pressure is being admitted into the lower
cap. The control spool moves upwards against the
spring assembly, blocking off the path between
channel C2 and the tank channel so that the oil
must flow through load-holding valve (1) into channel P and past the control edge of the spool to port
B2 and from there through rotor (75) to the undercarriage and the piston sides of stabilizer cylinders
(115 and 116).
The pressure opens a non-return valve in the twin
valve to the piston side so that the oil flows directly
into the cylinder. At the same time, the pressure
unblocks the second non-return valve by means of
an opening piston so that the outlet back to the
reservoir is open.

Raising
During raising of the stabilizers, proportional valve
Y202a is energized from the ESX and pilot pressure is admitted into the upper cap. The control
spool moves downwards against the spring assembly.
The oil from pump 2 flows via port A2 to the rod
sides of the stabilizer cylinders. The non-return
twin valve is again unblocked and traversed by the
oil flow in reverse direction.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 112

HYDRAULICS

WX210 - WX240

Stabilizer control spool

40000393-en

Travel direction

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Legend
P02

Pressure channel of pump 2

C2

Discharge channel for pump 2

Load-holding valve

Pressure channel ahead of A2 and B2

Pressure channel of pump 2

Discharge channel for pump 2

Load-holding valve

P1

Pressure channel ahead of A2 and B2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 113

5 - 114

HYDRAULICS

WX210 - WX240

Levelling blade cylinder (No. 115)

40000394-en

Fig. 1

Description
Legend
1

Levelling-blade cylinder, complete

Pilot-operated check valve on piston


side

Control piston

Pilot-operated check valve on rod side

The double-acting cylinder with pilot-operated twin


check valve is used for lifting and lowering of the
levelling blade.
For lowering of the blade, oil flows to port B and is
directly admitted via check valve (2) to the piston
side. Check valve (4) is opened at the same time
by control piston (3) for return oil discharge.
During lifting of the blade, the oil enters the cylinder at port A and flows via check valve (4) direct to
the rod side and to control piston (3). The control
piston opens check valve (2) for return oil discharge.
Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 115

Outrigger cylinder (No. 116)

40000395-en

Fig. 1

Description
Legend
1

Outrigger cylinder, complete

Pilot-operated check valve on piston


side

Control piston

Pilot-operated check valve on rod side

The double-acting cylinder with pilot-operated twin


check valve is used for extending and retracting of
the outriggers.
To extend the outriggers, oil flows to port B and is
directly admitted via check valve (2) to the piston
side. Check valve (4) is opened at the same time
by control piston (3) for return oil discharge.
Fig. 2

During retraction of the outriggers the oil enters the


cylinder at port A and flows via check valve (4)
direct to the rod side and to control piston (3). The
control piston opens check valve (2) for return oil
discharge.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 116

HYDRAULICS

WX210 - WX240

Stabilization variants

40000555-en

Description

Stabilization PL/A2 (No. 107)

In the different stabilization variants, the oil for


extension and retraction does not flow directly into
the cylinders, but into a solenoid valve combination which can be equipped with two, three or four
solenoid valves depending on the variant. The
solenoids are of the same design and have an
open center position.

The hydraulic diagram with P/N 4530235, sheet 4


of 7 shows the PL/A2 variant.

All solenoid valves are equipped with emergency


operation devices to permit raising of the outriggers after a power supply failure when pressure is
still available.
The solenoid valve combination is installed in the
center of the undercarriage.
The line transporting the oil from pump 2 to the
piston sides of the outrigger cylinders is for all
variants connected to port P of the valve combination. The lines to the piston-side ports of the cylinders are connected to the individual solenoid
valves. The rod-side ports are connected directly
to the control block via the rotor. The valve combination is moreover equipped with a line connected to port T.

When both preselector switches are activated, the


levelling blade and the A2 outriggers can be
moved in parallel. If only one preselector switch is
activated, the corresponding outrigger is the only
one that can be moved.

Stabilization A4 (No. 107)


The hydraulic diagram with P/N 4530235, sheet 5
of 7 shows the A4 variant.
This variant permits moving the four outrigger
cylinders in parallel if both preselector switches
are depressed. As an alternative, the outrigger
cylinders on the right or the left can be operated in
parallel.

Individual stabilization (No. 108)


Valve combination No. 108 in the undercarriage:

Ignition switch-on
After ignition switch-on, all solenoid valves are
energized so that the oil flow is stopped.

Actuating the preselector switches


By actuating the stabilization preselector switches
in the lefthand control console, the respective
solenoid valves are switched off. This is confirmed
by the corresponding LEDs lighting up.
The solenoid valves are set to the open zero position and the oil flow is enabled.

Stabilization A2 (No. 107)


The hydraulic diagram with P/N 4530235, sheet 3
of 7 shows variant A2.
When both preselector switches are activated, the
two outrigger cylinders can be moved in parallel.
Individual control of each outrigger is achieved by
switching on the one or the other solenoid valve.

The hydraulic diagram with P/N 4530235, sheet 6


of 7 shows the individual outrigger control variant
PL/A2.
When the three preselector switches are activated, the levelling blade and the A2 stabilization
can be moved in parallel. The preselector switches permit moving the levelling blade and the
outriggers independently of each other.
The outriggers can also be controlled individually.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Individual stabilization A4 (No. 109)


Valve combination No. 109 in the undercarriage:

5 - 117

By activating individual solenoids, there is moreover the possibility to lock out the pertaining outrigger cylinder while the others remain free to
move.
All outrigger cylinder can thus be operated individually.
This stabilization variant permits operating the
outrigger cylinders in any conceivable combination.
Reference in the text to "...outrigger
cylinders moving in parallel..." does
not imply that the outriggers move
synchronously up and down.
The outrigger cylinders with the lowest bearing resistance will move before the others do.

The hydraulic diagram with P/N 4530235, sheet 7


of 7 shows the individual outrigger control A4.
After actuation of the four preselector switches
solenoid valves Y48.1, Y48.2, Y48.3 and Y48.4 are
de-energized.
In this position they are open so that the four outrigger cylinders can be moved in parallel.
When solenoid valves Y48.1 and Y48.2 are off,
only the front outriggers can be moved in parallel.
When solenoid valves Y48.3 and Y48.4 are off,
only the rear outriggers can be moved in parallel.
The front or rear outriggers can thus be operated in
pairs.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 118

HYDRAULICS

WX210 - WX240

Hydraulic circuit diagram undercarriage, Part number 4530235

40000325-en

Legend
75. Hydraulic rotor with 10 channels
76. Electric rotor with 16 slip rings
100. Travel drive consisting of:
rigid axle ASP100/125
101. Multiple-disk speed-change gearbox
102. Travel oil motor A 6 VM HA with travel brake valve MHB for 20 km/h axle
102. Travel oil motor A 6 VM HA with travel brake valve MHB and adjustment with shutoff only for 25 km/h or 30 km/h axle
104. Nitrogen accumulator for parking brake action delay in conjunction with restrictor 1 mm
105. Control block consisting of:
solenoid valve Y21.2 for creep speed selection
solenoid Y62 for floating-axle support
solenoid Y16 for parking brake with emergency actuation
solenoid Y21.4 for shifting gears
106. Pressure switch S16.1 for parking brake pilot lamp, opening pressure = 30 bars
107. Solenoid valves Y48.3 and Y48.4 for outrigger individual control, sheet 3 of 7
107. Solenoid valves Y48.1 and Y48.4 for levelling blade/outrigger switch-over, sheet 4 of 7
107. Solenoid valves Y48.1 and Y48.4 for switching of stabilization right-hand side / left-hand side, sheet 5 of 7
108. Solenoid valves Y48.1, Y48.3 and Y48.4 for levelling blade / outrigger individual control, sheet 6 of 7
109. Solenoid valves Y48.1, Y48.2, Y48.3 and Y48.4 for outrigger individual control, sheet 7 of 7
110. Steering and floating axle ALPP100/125
111. Floating-axle cylinder with integrated shutoff valve and restrictor non-return valves
115. Levelling blade cylinder
116. Ourigger cylinder

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 119

Undercarriage with 25 (30) km/h axle, sheet 1 of 7

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 120

HYDRAULICS

WX210 - WX240

Undercarriage with 25 km/h axle, sheet 2 of 7

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 121

Undercarriage with A2 stabilization with individual control, sheet 3 of 7

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 122

HYDRAULICS

WX210 - WX240

Undercarriage levelling blade A2 stabilization, sheet 4 of 7

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 123

Undercarriage A4 stabilization, sheet 5 of 7

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 124

HYDRAULICS

WX210 - WX240

Undercarriage levelling blade A2 stabilization individual control, sheet 6 of 7

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 125

Undercarriage A4 stabilization individual control, sheet 7 of 7

Fig. 7

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 126

HYDRAULICS

WX210 - WX240

BOOM CYLINDER CIRCUIT


Schematic diagram with regeneration circuit

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000398-en

WX210 - WX240

HYDRAULICS

5 - 127

Description
The description is based on the schematic diagram and the section drawing of the control spool.
The circuit for the boom cylinders is fed by both
pumps. Double admission is only used for boom
raising. When a second function is activated at the
same time, the boom cylinders receive only the
flow from one pump.

Neutral

The return oil from the cylinder rod sides enters


the control block at port A3 and flows past the
control edge into the tank channel.

Boom lowering
During lowering of the equipment, proportional
valve Y241 is energized by the ESX and loadsensing pressure is admitted to the pump regulator of pump 1.

In neutral position, the flushing oil amounts from


both pumps flow past the control spool to the C1
and C2 channels and then past the other control
spools into the tank channel. The circulating pressure opens both load-holding valves (1) so that
the oil flows are combined in channel P (bridging
channel).

In addition, proportional valve Y203a is energized,


and pilot pressure admitted to the upper cap so
that the control spool moves downwards.

The secondary valves (3+4) protect the boom cylinders against inadmissibly high pressure peaks.

After opening of the pipe break protections, the


load pressure existing on the piston sides activates pressure sensor B74 (58), which sends a
corresponding current signal to the ESX.

The tank channel preloading pressure is available


via replenishing non-return valves on both sides of
the boom cylinders to prevent cavitation.

Activation of a function
Any activation of a function is detected by the
ESX. The virtual pressure switch DSL in the ESX
opens before the movement starts. The ESX
opens the solenoid valve Y113 in the pilot-control
unit (60) so that the pilot pressure gets to proportional valves Y203a and Y203b through the inlet
filter in port PV.

The pilot pressure from the upper cap opens also


the boom check valves or the alternative pipe
break protections to enable the return flow from
the cylinders.

In conjunction with the lowering action, the regeneration function is activated as long as there is
load pressure on the piston sides.
After the bucket has settled on the ground or
penetrated into the soil, the load pressure on the
piston side diminishes. The pressure drop is
evaluated by pressure sensor B74 and the ESX
energizes the proportional valves of the control
displacement in such a way that the regeneration
function is not operational.

Boom raising
When the equipment is raised, the ESX energizes
proportional valves Y241 and Y242 of the pump
control and load-sensing pressure is admitted to
both pump regulators at port X1.
In addition, proportional valve Y203b is energized
by the ESX so that pilot pressure gets into the
lower cap. The control spool moves upwards
against the spring.
The control edges close the C1 and C2 channels
and the oil from both pumps must flow via the
load-holding valves (1) into the P channel (bridging channel) and past the open control edge to
port B3. The oil flows through B3 to the boom
cylinder piston sides through the pipe break protections at the boom cylinder or through the alternative boom check valve in control block port B3.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 128

HYDRAULICS

WX210 - WX240

Control spool

Boom lowering pressure


without regeneration
function

Boom lowering with


regeneration function

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 129

Description
The description is based on the schematic diagram and the section drawing of the control spool.

Boom lowering with pressure, bucket


touching or penetrating into the soil

Boom lowering with regeneration function


(with load pressure on the piston sides)

(without load pressure at the pistons sides, the


regeneration function is not operational)

Proportional valve Y203a is controlled by a lower


current signal so that the downward stroke of the
control spool is shorter. The control edge to channel C1 is slightly restricted so that a partial flow
from pump 1 passes via the load-holding valve (1)
into the P channel (bridging channel) and via the
control notches of the control spool into the A3
channel and to the rod sides.

When the bucket is set on the ground, the pressure drop at the piston sides is detected by sensor
B74 and signals a current change to the ESX. The
ESX now increases the current to proportional
valve Y203a so that the control spool stroke becomes longer.

The other partial amount of oil from pump 1 flows


via the restricted control edge to the C1 channel
and the control spools behind.
The oil from pump 2 in channel P02 can flow past
the long waist of the control spool into channel
C2. Pump 2 has no influence on the lowering
movement.
The return oil from the piston sides of the cylinders flows via port B3 and through staggered
transverse ducts in the control spool into its axial
center bore. The return pressure opens the lower
non-return valve (6) and the oil, together with the
partial flow from pump 1, leaves at port A3 and
flows to the two rod sides of the boom cylinders.
The piston sides displace more oil than the rod
sides can absorb. The excess oil generates a
return pressure opening the upper preloading
valve (5) in the hollow piston to the tank channel.
The preloading pressure thus generated ensures
filling of the rod sides during fast lowering movements.

The control edge closes channel C1 and the oil


from pump 1 flows completely through the lower
load-holding valve (1) into the P channel (bridging
channel) and then past the open control edge to
port A3 and on to the rod sides of the boom cylinders.
The return oil from the piston sides flows through
the opened pipe break protections or through the
alternative boom check valve in port B3 and then
through the transverse ducts into the axial center
bore of the control spool. Since the lower nonreturn valve (6) remains closed under the influence of the high pressure from pump 1, the return
oil must flow completely via the upper preloading
valve (5) into the tank channel. The upper nonreturn valve (5) with its preloading pressure is
ready to fill the rod sides via the lower non-return
valve (6) if there is a risk of cavitation in the rod
sides when the machine is excavating.

The control of pump 1 during boom lowering ensures a transition without delay from pressureless
lowering to pressure build-up when the digging
tool penetrates into the soil.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 130

HYDRAULICS

WX210 - WX240

Travel direction

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 131

Legend
P01

Pressure channel of pump 1

Load-holding valve

C1

Connecting channel for pump 1

Plug

P02

Pressure channel of pump 2

Secondary valve piston side

C2

Connecting channel for pump 2

Secondary valve rod side

P channel (bridging channel)

Preloading valve

A3

Boom cylinder rod side

Non-return valve

B3

Boom cylinder piston side

Preloaded tank channel

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WX210 - WX240

Pipe break protection valves (Nos. 202 and 210)

40000399-en

Description
Pipe break protection valves are safety valves that
are installed directly at the cylinders. Depending
on the function and the use of the cylinder, the
pipe break protections are installed at the pistonor rod-side connection of a cylinder.
The pipe break protection valve is a hydraulically
operated non-return valve with variable flow cross
section retaining the load pressure of the oil column in the cylinder without leakage.
Inadmissibly high cylinder pressures are reduced
via the secondary valve to the control block and
from there via the pertaining secondary valve
towards the reservoir.
Fig. 1

Legend
A

Control block connection

Cylinder connection

Pilot-pressure connection

Compensation line connection, only used


with boom cylinders

SV

Secondary valve, adjustable

Fig. 2

The STOP situation in the drawing opposite


shows a pipe break protection valve in closed
condition. The cylinder pressure acts via port B on
the spring cavity behind the non-return valve and
at the secondary valve. The valve piston is closed
by the pressure assisted by spring force.
The UP situation shows the oil flow from the control block via port A through the valve piston
opened by pressure to port B in the cylinder compartment.
The DOWN situation shows how the oil column
from the cylinder can flow to the contol block after
opening of the pipe break protection. Opening is
effected by pilot pressure at port X acting on the
pilot-control piston. The pilot-control piston is displaced against the compensator springs with the
plunger opening a pressure-relief valve in the
valve piston against the spring. The spring cavity
is depressurized towards the control block and the
valve piston opens in proportion to the value of
the pilot pressure at port X.
The STOP position is reached again by shutting
off the pilot pressure. The pilot-control piston ist
retracted by the springs. The pressure-relief valve
is closed by spring force and the cylinder pressure
builds up in the spring cavity behind the valve
piston. The valve piston is forced by the load
pressure on its seat in the valve, thus retaining the
oil column in the cylinder without leakage.

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WX210 - WX240

HYDRAULICS

5 - 133

Fig. 3

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 134

HYDRAULICS

WX210 - WX240

Boom check valve with emergency operation capability

Fig. 5

Description

The check valve (1) serves the purpose of retaining the load pressure at the piston side of the
boom cylinders without leakage.
The load pressure prevailing in the cylinders when
the equipment is up is admitted via port B3-Kf to
the rod side of the check valve where an opening
force is active. At the same time, the load pressure
is admitted via the orifice in restrictor non-return
valve (2) to the spring cavity and closes the check
valve assisted by spring force.
During boom lowering, the pilot pressure (5) opens
unlocking valve (3) so that the closing pressure
from the spring cavity can escape towards leakage
oil channel (6). When the equipment is raised, the
pump pressure opens the check valve, with the oil
being displaced from the spring cavity via nonreturn valve (2).
Emergency operation:

In a emergency (boom cannot be lowered), the


unblocking valve (3) can be actuated by means of
screw (4). When screw (4) is turned in, valve (3)
opens the passage to leakage oil channel (6) of
the control block. The lowering speed of the
equipment depends on the opening cross section
in unlocking valve (3).

Fig. 6

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WX210 - WX240

HYDRAULICS

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5 - 135

5 - 136

HYDRAULICS

WX210 - WX240

BUCKET CYLINDER CIRCUIT

40000400-en

Schematic diagram

Fig. 1
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WX210 - WX240

HYDRAULICS

5 - 137

Description

Bucket cylinder extension

The description is based on the schematic diagram and the section drawing of the control spool.

When the function is activated, proportional valve


Y204a is energized by the ESX and pilot pressure
gets into the lower cap. The control spool moves
downwards against the spring assembly.

The circuit for the bucket cylinders is fed by pump


1 and pump 2. The combination of the oil flows
(double admission) is only used when the bucket
is actuated alone.
When a second function is activated at the same
time, the bucket cylinder receives only the flow
from one pump.

Neutral
In neutral position of the control spool, the flushing
oil amounts from pump 1 and pump 2 flow past
the control spool to the C1 and C2 channels and
then past the other control spools into the tank
channel.
The circulating pressure opens both load-holding
valves (1) so that the oil flow from pump 1 and the
flow from pump 2 are combined in channel P
(bridging channel).
The non-return valves of the bucket parallel circuit
(2) are equally opened by the circulating pressure
of the pumps.
The pressure generated by the tank channel preloading valves is available via replenishing nonreturn valves, which are part of the secondary
valves (3+4), on both sides of the bucket cylinder
to prevent cavitation.

Channels C1 and C2 are closed and the oil from


both pumps must flow via the load-holding valves
(1) into the P channel (bridging channel) and past
the control edge to port A4 and on to the piston
side of the bucket cylinder.
The oil returning from the rod side flows through
the adjustable restrictor non-return valve (206)
and the control block port B4 to the tank channel.

Bucket cylinder retraction


During retraction of the bucket cylinder, proportional valve Y204b is energized by the ESX and
the pilot pressure is admitted to the lower cap.
The control spool moves upwards against the
spring.
The oil flows through port B4 and restrictor nonreturn valve (206) to the rod side of the bucket
cylinder.
The oil returning from the piston side flows
through port A4 into the tank channel.

Activation of a function
The activation of a bucket function is detected by
the ESX. Virtual pressure switch DSL opens before the movement begins. The ESX opens the
solenoid valve Y113 in the pilot-control unit (60)
so that the pilot pressure gets to proportional
valves Y204a and Y204b through an inlet filter in
control block port PV.
The ESX energizes also proportional valves Y241
and Y242 of the pump control to admit loadsensing pressure to the pump regulators at port
X1.

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5 - 138

HYDRAULICS

WX210 - WX240

Control spool

Travel direction

Fig. 2

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WX210 - WX240

HYDRAULICS

5 - 139

Legend
P1

Pressure channel of pump 1

A4

Bucket cylinder piston side

P01

Pressure channel of pump 1

B4

Bucket cylinder rod side

C1

Connecting channel for pump 1

Load-holding valves

P2

Pressure channel of 2

Bucket parallel connections

P02

Pressure channel of 2

Secondary valve rod side

C2

Connecting channel for pump 2

Secondary valve piston side

P channel (bridging channel)

Preloaded tank channel

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 140

HYDRAULICS

WX210 - WX240

Bucket parallel connection circuit

Stroke 3 mm

Fig. 3

Legend
1

Valve housing

Inlet orifice

Non-return valve

Spring

Description
The bucket parallel connection permits executing
a controlled bucket movement together with a
boom and stick movement. This is of use when
three or more cylinder functions are summoned at
the same time.
The oil supply for the boom function is ensured by
pump 1 and that of the stick function by pump 2.
The bucket function in between receives partial oil
flows from pump 1 and 2 via both bucket parallel
connection valves.
Since this a parallel connection, the higher load
pressure of the boom, for instance, has an influence on the amount of oil supplying the bucket
cylinder. An inlet orifice in each bucket parallel
connection valve prevents the boom and/or stick
function from being significantly influenced when
the bucket movement is activated in parallel.

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

Restrictor non-return valve (No. 206)

HYDRAULICS

5 - 141

Description
The restrictor non-return valve is a combination of
an adjustable restrictor valve and a non-return
valve. The valve is installed on the rod side of the
bucket cylinder.
The valve serves the purpose of extending the
cylinder at restricted flow so that there is no risk of
oil shortage on the piston side of the cylinder.
In this case, the return oil is evacuated from the
rod side through the adjustable throttling section.
Setscrew (4) limits the stroke of restrictor piston
(2) and thus the cross-section open to the flow.

Fig. 5

If the restrictor piston is turned with


the setscrew completely down to
the stop, there is still part of the
cross-section remaining open with
the result of a marked slow-down of
the cylinder movement. The oil
would moreover be heated up considerably.

When the bucket is emptied, i.e. when the cylinder


is retracted, the oil flows through the non-return
valve unthrottled into the rod side of the cylinder.

Fig. 6

Legend
1

Housing

Restrictor no-return piston

Spring

Setscrew

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 142

HYDRAULICS

WX210 - WX240

Ballcocks (No. 207)

Fig. 7

Description
Legend
1

Ballcock, piston side

Ballcock, rod side

Coupling, grab closed

Coupling, grab opened

206

Restrictor non-return valve

The machine is switched over from backhoe


bucket to grab operation and vice versa with two
ballcocks.
The retracted bucket cylinder is blocked off on the
piston side with ballcock (1) and on the rod side
with ballcock (2).
For switching, both ballcocks must be used.
For safety reasons, the housing of ballcock (2) is
equipped with a pressure-limiting valve protecting
the rod side of the bucket cylinder against inadmissibly high pressures as a result of erroneous
operation of the ballcocks.
Blocking off only the ballcock on the
rod side (2) for switching over constitutes a case of erroneous operation.

Fig. 8

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WX210 - WX240

HYDRAULICS

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5 - 143

5 - 144

HYDRAULICS

WX210 - WX240

STICK CYLINDER CIRCUIT WITH REGENERATION FUNCTION

40000401-en

Schematic diagram

Fig. 1
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 145

Description

General lowering of stick

The description is based on the schematic diagram and the section drawing of the control spool.

During lowering of the stick, proportional valve


Y205a is energized and load-sensing pressure is
admitted to the upper cap. The pilot pressure
moreover unblocks the check valve in port B5.

The stick cylinder circuit is fed by pump 1 and


pump 2. The combined oil flows (double admission) act in both cylinder directions.
When a further cylinder is activated at the same
time, the stick cylinder receives only the oil flow
from one pump.

Neutral
In neutral position, the flushing oil amounts from
both pumps flow past the control spool to the C1
and C2 channels and then past the other control
spools into the tank channel. The circulating pressure opens both load-holding valves (1) so that
the oil flows from both pumps are combined in
channel P.
The secondary valves protect the cylinder on both
sides and the lines against pressure peaks.
The tank channel preloading pressure is available
via the replenishing non-return valves to both
cylinder sides to prevent cavitation.

Activation of a function
Any activation of a function is detected by the
ESX. The virtual pressure switch DSL in the ESX
opens before the movement starts. The ESX
opens the solenoid valve Y113 in the pilot-control
unit (60) so that the pilot pressure gets to proportional valves Y205a and Y205b through the inlet
filter in port PV. The ESX energizes also proportional valves Y241 and Y242 of the pump control
to admit load-sensing pressure to the pump regulators at port X1.

Extending the stick


Proportional valve Y205b is energized by the ESX
and pilot pressure gets into the lower cap and
moves the control spool upwards against the
spring.

The control spool moves downwards and the


transverse bore in the hollow piston opens the
passage to rod side channel B5. The oil returning
from the cylinder rod side flows through the transverse duct into the axial center bore of the control
spool and reaches the lower non-return valve (1)
and the upper preloading valve (2).
The piston side connection A5 of the cylinder is
filled with oil from both pumps via the P channel.

Pressureless lowering of stick


As long as the stick has not reached the ground
during lowering, piston side A5 is virtually without
pressure. The oil returning from the rod side which
is preloaded in the center bore by non-return
valve (2) opens the lower non-return valve (1),
flows through the transverse duct and fills piston
side A5 of the stick cylinder together with the oil
flows from the pumps. The greater oil volume on
the piston side causes the stick to sink faster. At
the same time, the staggered transverse ducts in
the control spool throttle the return flow from the
rod sides in such a way that any uncontrolled
swinging of the stick caused by cavitation is
avoided.

Lowering the stick with pressure, excavating tool penetrates into the ground
When the bucket rests on the ground, the pressure on the piston side A5 rises because of the
resistance offered by the ground. This pressure is
admitted to the lower non-return valve (1) on the
spring side. The valve closes against the preloading pressure in the center bore. The oil returning
from rod side B5 must now flow completely via
preloading valve (2) to the tank channel.

The control edges close the C1 and C2 channels


and the oil from both pumps must flow via the
load-holding valves into the P channel and past
the open control edge to port B5. The oil flow
opens the controlled check valve in port B5 and
passes to the rod side of the stick cylinder. The
return oil flows via port A3 into the tank channel.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 146

HYDRAULICS

WX210 - WX240

Control spool

Fig. 2

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WX210 - WX240

HYDRAULICS

5 - 147

Stick check valve with emergency operation capability

Fig. 3

Legend
P01

Pressure channel of pump 1

A5

Stick cylinder- piston side

C1

Connecting channel for pump 1

B5

Stick cylinder- rod side

P02

Pressure channel of pump 2

Preloaded tank channel

C2

Connecting channel for pump 2

Non-return valve

P channel (bridging channel)

Preloading valve

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5 - 148

HYDRAULICS

WX210 - WX240

Description
The check valve (1) serves the purpose of retaining the load pressure at the rod side of the stick
cylinder without leakage.
The load pressure prevailing in the cylinder when
the stick is extended is admitted via port B5-Rf to
the rod side of the check valve where an opening
force is active. At the same time, the load pressure
is admitted via the orifice in restrictor non-return
valve (2) to the spring cavity and closes the check
valve assisted by spring force.
During stick lowering, the pilot pressure (5) opens
unlocking valve (3) so that the closing pressure
from the spring cavity can escape towards leakage
oil channel (6).
When the stick is extended, the pump pressure
opens the check valve, with the oil being displaced
from the spring cavity via non-return valve (2).

Emergency operation
In a emergency (stick cannot be lowered), the unblocking valve (3) can be actuated by means of
screw (4).

Fig. 4

When screw (4) is turned in, valve (3) opens the


passage to leakage oil channel (6) of the control
block. The speed with which the stick is lowered
depends on the opening cross section in unlocking
valve (3).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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5 - 149

5 - 150

HYDRAULICS

WX210 - WX240

ADJUSTING CYLINDER CIRCUIT WITH


PRESSURE COMPENSATOR AND RELIEF VALVE

40000556-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 151

Description

Activation of a function

The description is based on the schematic diagram and the section drawing of the control spool.

Any activation of the adjusting cylinder is detected


by the ESX. The virtual pressure switch DSL in
the ESX opens before the movement starts.

The oil from pump 2 flows into two pump channels


in the control block. The channels are labelled P2
and P02. Channel P2 passes through the blanking
plate (55) and back into the control block (50) as
channel P02.
The adjusting cylinder circuit is fed by a partial
flow from pump 2 via a pressure compensator and
channel P2. The adjusting cylinder receives a
load-dependent discharge flow. The amount of oil
from pump 2 that is not needed for the adjusting
cylinder returns through the relief valve and bypass channel C2 back into the P02 channel where
it is available to subsequent cylinder functions.

Neutral
In neutral position of the adjusting cylinder, the
flushing oil from pump 2 flows into channel P2. It
is available at the closed relief valve and flows at
the same time to the pressure compensator.
The oil moreover flows through channel P02 past
the waist of the control spool into channel C2 and
then via the following control spools into the tank
channel. The tank channel preloading valves generate circulation pressure which is available via
the replenishing non-return valves at the secondary valves on both sides of the adjusting cylinder.
Secondary valves (3+4) protect the adjusting cylinder against inadmissibly high pressure peaks.

Secondary valve in pipe break


protection system:

The ESX opens the solenoid valve Y113 in the


pilot-control unit (60) so that the pilot pressure
gets to proportional valves Y206a and Y206b
through the inlet filter in port PV. The ESX energizes also proportional valve Y242 of the pump
control to admit load-sensing pressure to the
pump regulator of pump 2 at port X1.

Retracting the boom adjusting cylinder,


extending the upper boom section
Proportional valve Y206b is energized by the ESX
and pilot pressure gets into the lower cap and
moves the control spool upwards against the
springs. The control edge closes the P02 channel
whereby the pump pressure rises. Beyond 15
bars, the pressure compensator opens and the oil
is available at the opening cross-section of the
control spool.
Further flow details: see pressure compensator.

Extending the boom adjusting cylinder,


lowering the upper boom section
During extension of the adjusting cylinder, proportional valve Y206a is energized and load-sensing
pressure is admitted to the upper cap with the
control spool being displaced downwards against
the springs. At the same time, the pipe break protection opens so that the oil can return to the tank.
Beyond 15 bars, the pressure compensator opens
and the oil is available at the opening cross-section of the control spool.
Further flow details: see pressure compensator.

The rod side of the adjusting cylinder is equipped with a pipe break
protection with a secondary valve of
its own. In the secondary case, this
valve opens so that the control piston in the pipe break protection
opens, too, and that the peak pressure passes through the line to port
A6 and through secondary valve (4)
into the tank channel.

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5 - 152

HYDRAULICS

WX210 - WX240

Control spool

Travel direction

T
B6 - Kf
P2

PZ
P02

1
C2
PLS
2
P1
A6 - Rf

PLS
C1
P01
T
Y206a

Y206b
Fig. 2

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WX210 - WX240

HYDRAULICS

5 - 153

Legend
P1

Pressure channel of pump 1

A6

Adjusting cylinder rod side

P01

Pressure channel of pump 1

B6

Adjusting cylinder piston side

C1

Connecting channel for pump

PLS

Load-pressure channel

P2

Pressure channel of pump 2

Pressure compensator

P02

Pressure channel of pump 2

Plug

C2

Channel to stick control spool

Secondary valve - piston side

PZ

Regulated pressure from compensator

Secondary valve - rod side

Preloaded tank chanel

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5 - 154

HYDRAULICS

WX210 - WX240

Boom adjusting cylinder control spool with compensator

Fig. 3

Boom adjusting cylinder control spool with pressure relief valve

Fig. 4

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WX210 - WX240

HYDRAULICS

5 - 155

Pressure compensator for adjusting cylinder


Function
The function of the pressure compensator is to maintain the discharge flow to the cylinder as determined by
the cross-section of the control spool even under varying load pressures.
The compensator is represented in the figures in its three states of operation.

Pump 2

Pressure compensator

Stroke 8 mm

Pressureless state

Orifice

Control piston

Spring 15 bar
Charge pressure

P-channel

Fig. 5

Operation
After engine start, pump 2 supplies oil to the inlet channel of the pressure compensator. During activation of
a function, the pump 2 generates a pressure of >15 bars. This pressure is admitted through the transverse
bore and the orifice and builds up behind the piston. The force FP moves the piston against the spring
whereby the non-return function of the piston is disabled. The oil from pump 2 flows into the P channel and
to the control spool whose control edge is still closed.
Pressure compensator

Pump 2

Activation of a function

FP

FF

Non-return valve
open
P-channel

Fig. 6

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5 - 156

HYDRAULICS

Pressure compensator

WX210 - WX240

Pump 2

Regulation

Regulating
edge

FP

FF + FLS

Pressure in channel P
FF
FLS
FP

Spring force
Force of the load pressure
Force of the pressure in
channel P

Control edge of
the control spool
Charge pressure

Adjusting cylinder

Fig. 7

Adjusting cylinder activated


When the control spool is activated, the control
edge is opened. The opening cross-section of the
egde determines the discharge flow to the adjusting cylinder and thus its moving speed. On account of the hydraulic resistance in the cylinder, a
load pressure is generated.
Between the regulating edge of the compensator
and the control edge of the control spool, i.e. in
the P channel, the pressure rises. This pressure
rise equally causes the force FP acting on the
piston to increase.
At the same time, the load pressure of the cylinder
is available in the spring cavity of the pressure
compensator.
This load pressure with its force FLS together with
the spring force FF act against the piston.

By the forces acting from both sides, the piston is


positioned in such a way that the resulting flow
cross-section at the regulating edge is such that a
pressure build-up occurs in channel P.
By means of the control edge, this pressure in
channel P generates a pressure differential with
respect to the load pressure in the cylinder.
The compensator keeps this pressure differential
constant as long as the control spool is not moved
to another position.
To each change of the load pressure, the piston
responds briefly by changing the cross section at
the regulating edge until the forces acting on the
piston are again in equilibrium. The pressure differential before and behind the control spool edge
is thus kept constant.
The discharge flow to the cylinder is therefore
indepedent of the load pressure. The result is that
even under varying load conditions the cylinder always moves at the same speed.

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WX210 - WX240

HYDRAULICS

5 - 157

Pressure compensator, relief valve and LS pressure limiting valve

40000558-en

Travel direction

T
B6 - Kf

PLS

P2

2
C2

1
MS
PLS

PZ

A6 - Rf

Fig. 1

Legend
P2

Pressure channel of pump 2

Pressure compensator

C2

Channel to stick control spool

Relief valve

PZ

Regulated pressure from compensator

LS pressure limiting valve

PLS

Load-pressure channel

Shuttle valve

A6

Adjusting cylinder- rod side

Preloaded tank chanel

B6

Adjusting cylinder- piston side

MS

Port with sensor B 239

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 158

HYDRAULICS

WX210 - WX240

Relief valve

Fig. 2

Description
For the oil from pump 2, the relief valve constitutes a by-pass of the adjusting control spool towards the stick control spool. When the adjusting
and the stick cylinder are actuated at the same
time, the oil flow of pump 2 is divided to serve
both functions.

The load pressure of the adjusting cylinder


reaches the spring cavity and acts together with
the force of the spring on the piston. In order to
maintain the connection with the channel C2, the
pump pressure must now overcome the spring
force plus the force of the LS pressure.

In the original position, the springs forces the piston into the blocking position.

The LS pressure is limited by means of a presettable pressure-limiting valve.

In operation, the pressure from pump 2 is admitted to the piston against the spring force. If the
pump pressure reaches 35 bars, the piston opens
and the oil flows into channel C2 and to the stick
control spool.

When the adjusting cylinder is moved to its limit


stop position, the pressure build-up reaches 320
bars (measured at measuring point M2).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 159

Pipe break protection valve


Description

Pipe break protection valves are safety valves that


are installed directly at the cylinders. Depending
on the function and the use of the cylinder, the
pipe break protections are installed at the pistonor rod-side connection of a cylinder.
The pipe break protection valve is a hydraulically
operated non-return valve with variable flow cross
section retaining the load pressure of the oil column in the cylinder without leakage.
Inadmissibly high cylinder pressures are reduced
via the secondary valve to the control block and
from there via the pertaining secondary valve
towards the reservoir.

Fig. 1

Legend
A

Control block connection

Cylinder connection

Pilot-pressure connection

Connection for compensation line, only


used with boom cylinders

SV

Secondary valve, adjustable

Fig. 2

The STOP situation in the drawing opposite


shows a pipe break protection valve in closed
condition. The cylinder pressure acts via port B on
the spring cavity behind the non-return valve and
at the secondary valve. The non-return piston is
closed by the pressure assisted by spring force.
The UP situation shows the oil flow from the control block via port A through the non-return piston
opened by pressure to port B in the cylinder compartment.
The DOWN situation shows how the oil column
from the cylinder can flow to the contol block after
opening of the pipe break protection. Opening is
effected by pilot pressure at port X acting on the
pilot-control piston. The pilot-control piston is displaced against the compensator springs with the
plunger opening a pressure-relief valve in the nonreturn piston against the spring. The spring cavity
is depressurized towards the control block and the
valve piston opens in proportion to the value of
the pilot pressure at port X.
The STOP position is reached again by shutting
off the pilot pressure. The pilot-control piston ist
retracted by the springs. The pressure-relief valve
is closed by spring force and the cylinder pressure
builds up in the spring cavity behind the nonreturn piston. The non-return piston is forced by
the load pressure on its seat in the valve, thus
retaining the oil column in the cylinder without
leakage.

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5 - 160

HYDRAULICS

WX210 - WX240

Fig. 3

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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5 - 161

5 - 162

HYDRAULICS

WX210 - WX240

COMBINED FUNCTIONS

40000559-en

Parallel actuation of boom, bucket, adjusting and stick cylinder

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 163

Description
For this combination of cylinder functions, the figure represents the oil flows of pump 1 and pump 2.
The pilot pressure is available via port PV at the
proportional valves for control spool adjustment. In
the example chosen, the ESX energizes the proportional valves Y203b, Y204b, Y205b and Y206b
whereby the pilot pressure gets into the lower caps
and displaces the control spools upwards.
The oil from pump 1 flows through channel P01 to
the boom cylinder control spool and then via the
load-holding valve into channel P past the control
edge through the boom check valve to port B3-Kf
and on to the boom cylinders. Channel C1 is
closed by the control edge so that the downstream
control spool for the bucket cylinder receives no oil
from channel P01.
The load pressure building up in the boom circuit
also gets into parallel channel P1 where the bucket
parallel valve is installed.
Since the control spool of the bucket is at the upper end, a partial amount of oil from pump 1 flows
with the boom load pressure through the bucket
parallel valve. The load-holding valves are closed
and the oil flows past the control edge to port B4Rf and on to the bucket cylinder.
The partial oil flow to the bucket cylinder depends
on the restrictor orifice in the bucket parallel valve
and the load pressure in the boom circuit.
The oil flow from pump 2 gets into channel P2 and
through the blanking plate into channel P02.
Channel P02 is closed by the control edge at the
adjusting spool.

The oil from pump 2 flows through the pressure


compensator into the PZ channel and past the
open control edge of the adjusting spool to port
A6-Rf and to the adjusting cylinder. The load pressure generated is admitted to the pressure compensator as load-sensing pressure. The compensator supplies a regulated pressure which is available through the orifice of the control spool edge
as load-pressure-independent discharge flow to
the adjusting cylinder.
The load pressure oil of the adjusting cylinder
flows also through the PLS channel and the shuttle
valve to the relief valve and supports opening of
the spring.
The oil flow from pump 2 is admitted to the relief
valve at the input side.
The relief valve opens when the pressure of pump
2 has overcome the load pressure and the spring
force at the other end. The oil from pump 2 thus
pressurized flows through the by-pass channel
behind the adjusting spool and into channel C2
and on to the displaced stick control spool. Its control edge closes channel P02 and the partial
amount of oil from pump 2 flows via the loadholding valve into the P channel. The oil then flows
past the open control edge through the check
valve to port B5-Rf and to the stick cylinder.
The preloaded oil from pump 2 also flows through
channel P2 to the second bucket parallel valve.
The higher of the load pressures from pump 1 or
from pump 2 prevails at the bucket parallel valves
and gets to the bucket cylinder. If the load pressures are the same value, partial volumes from
both circuits flow into the bucket cylinder.
As a result, it is possible to control four simultaneously actuated cylinder functions almost independently of one another with only two pump circuits.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 164

HYDRAULICS

WX210 - WX240

HYDRAULIC HAMMER CIRCUIT WITH BOOM ADJUSTING


EQUIPMENT

40000560-en

Schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 165

Description
The description refers to the schematic diagram
and to the sectional drawing of the control spool.
The hydraulic hammer circuit is supplied with oil
from pump 2. The circuit comprises a pressure
compensator and an electrically operated proportional pressure cut-off.

Neutral
In neutral position of the control valve, the oil from
pump 2 flows into channel P2 of the control block
and to the pressure compensator.
Moreover, the oil flows through the blanking plate
into channel P02 and past the hammer control
spool on to the other control spools into the tank
channel.

Switching on the hammer


The hammer is switched on by depressing the corresponding rocker switch. The control unit activates power stages 6 or 7, the pedal is switched
over to hammer operation and the hammer symbol is displayed on the display screen together
with a number representing the preset hammer
performance.

Activating the hammer with joystick


pushbutton or pedal
The ESX detects the activated state and switches
on solenoid valve Y113 in the pilot control unit so
that pilot pressure can get into the control block
via port PV..
The ESX also energizes proportional valves Y241
and Y242 for the pump control, and the loadsensing pressure gets to both pump regulators..
IMORTANT: Pump 1 needs load-sensing pressure for the cooling circuit
When the button for continuous hammer operation
is pressed, the ESX signals the reference value
on the CAN bus and the load-limit regulator energizes proportional valve Y207a with the control
spool performing its maximum downward stroke

If the hammer is operated by means of the pedal,


proportional valve Y207a delivers a partial oil flow
displacing the control spool downwards in proportion to the pedal excursion.
The load pressure built up during hammer operation gets through the load pressure tap in the control spool into the PLS channel. The load pressure
passes through the 0.8 orifice to the pressure
compensator and to the electrical pressure cut-off
valve Y239.2.

Performance setting
The hammer pressures that can be preset on the
display unit influence the electrical pressure cutoff valve Y239.2 via the ESX in such a way that
the corresponding load-sensing pressures are
limited by means of different control currents. This
means that the pressure compensator can be fed
with presettable load-sensing pressures. The
pressure compensator thus makes preset regulated pressures available to the PZ channel and to
the control spool.
The discharge flows that can be preset on the
display unit are transmitted by the ESX as reference values to the CAN bus which the load-limit
regulator hands on to proportional valve Y207a.
The resulting pilot-control pressures produce different control spool displacements and opening
cross sections at the control edges.
At the same time, the ESX supplies the corresponding current level to proportional valve Y242
in order to enable pump 2 to meet the oil demands.
Sensor B239 at the MS port is needed for calibration purposes.

Oil flow
The oil flows through the opening section at the
control spool to port B7 and then on to the hydraulic hammer.
The hammer pressure is also available at port
B7.1. On request of the customer, this port can be
equipped with frequency switching solenoid valve
Y39.3 (hammer impact cycle change).
The return oil from the hammer flows through the
return-flow filter into the reservoir.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 166

HYDRAULICS

WX210 - WX240

Hydraulic hammer control spool

Travel direction
2

5
T
LS
B7.1

B7

P02

PZ

C2

1
MS
P2

3
4
PLS

A7
5

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 167

Legend
P2

Pressure channel pump 2

LS

Load-pressure

P02

Pressure channel pump 2

PLS

Load-pressure channel

C2

Channel to adjusting control spool

MS

Port with sensor B239

PZ

Regulated pressure from compensator

Pressure compensator

Preloaded tank channel

Electrical pressure cut-off Y239.2

B7

Hammer pressure port

Shuttle valve

B7.1

Frequency switching port

Orifice 0.8 in LS channel

A7

closed

Plug

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 168

HYDRAULICS

WX210 - WX240

Electrical circuit diagram, hammer equipment

40000445-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 169

5 - 170

HYDRAULICS

WX210 - WX240

HAMMER CIRCUIT WITH AUXILIARY FUNCTION


(BOOM ADJUSTING EQUIPMENT)
Schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000561-en

WX210 - WX240

HYDRAULICS

Hammer circuit with auxiliary function like


shears or crusher with boom adjusting
equipment, description
The description is based on the schematic diagram and the section drawing of the control spool.
The circuit is supplied from pump 2. The hammer
circuit comprises a pressure compensator combined with an electrical pressure cut-off function.
For shears operation, only the compensator is
used.

Neutral
In neutral position of the control spool, the oil from
pump 2 flows through channel P2 to the pressure
compensator and then into channel P02 past the
hammer/shears control spool and via the other
control spools to the tank channel.

Activating the hammer


To activate the hammer, depress the rocker
switch. The control unit activates power stages 6
or 7, the pedal is switched over to hammer operation and the hammer symbol appears on display
together with a number representing the selected
hammer performance level. Solenoid valve Y39.9
moreover connects the hammer return line automatically with the hydraulic reservoir.

Starting the hammer operation with joystick pushbutton or pedal

5 - 171

When the hammer is controlled by means of the


pedal, proportional valve Y207a receives partial
flows displacing the control spool downwards in
proportion to pedal excursion.
The load pressure building up during hammer
operation gets through the load-pressure tap in
the control spool into the PLS channel. The load
pressure passes through orifice 0.8 to the pressure compensator and to the electrical pressure
cut-off valve Y239.2.

Performance setting
The hammer pressures preselected on the display
unit influence the electrical pressure cut-off valve
Y239.2 in such a way that the different currents
limit the load-sensing pressures accordingly. This
means that the pressure compensator is fed with
presettable LS pressures so that it can make predefined regulated pressures available to the PZ
channel (bridging channel) and the control spool.
The discharge flows preselected on the display
unit are transmitted by the ESX to the CAN bus as
reference values which are passed on by the
load-limit regulator to proportional valve Y207a.
The resulting pilot pressures produce variable
control spool strokes and opening cross sections
at the control spool edges..
At the same time, the ESX transmits the corresponding current signal to proportional valve Y242
so that pump 2 can meet the oil demands.

The ESX detects the hammer operation and


switches on solenoid valve Y113 in the pilotcontrol unit so that pilot pressure gets to the control block via port PV.

Sensor B239 at the MS port is necessary for calibration purposes.

The ESX energizes proportional valves Y241 and


Y242 for pump control and load-sensing pressure
is admitted to both pump regulators.

The preset discharge flow passes via the control


spool opening cross-section to port B7 and then to
the hydraulic hammer.

Pump 1 needs load-sensing pressure for the cooling circuit.

If the pushbutton for continuous hammer operation is pressed, the ESX transmits the reference
value over the CAN bus and the load-limit regulator energizes proportional valve Y207a, whereby
the control spool performs its maximum downward
stroke.

Oil flow

The oil returning from the hammer flows to hammer by-pass valve (90) port HR, through the unlocked non-return valve and via port C to the return-flow filter in the hydraulic reservoir.
The non-return valve in control spool (7) prevents
the tank channel preloading pressure from escaping through hammer by-pass valve (90). For the
same reason, the pressure-limiting valve at port
A7 is not equipped with a replenishing non-retrun
valve.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 172

HYDRAULICS

WX210 - WX240

Activating the shears

Oil flow during closing of the shears

To activate, depress the rocker switch. The control permits selection of all available performance
levels and the shears symbol appears on display.

The adjustment of the control spool blocks the


passage from channel P2 to channel C2.

Moreover, solenoid valve Y39.9 in hammer bypass valve (90) is activated electrically.

Operating the shears with the pedal


The ESX senses the operation and activates solenoid valve Y113 in the pilot control unit for
switching pilot pressure into the circuit. The pilot
pressure gets into the control block via port PV.
The ESX energizes proportional valve Y242 for
pump control and load-sensing pressure is admitted to the regulators of pump 2.
The ESX transmits a pedal-excursion and direction-dependent current signal to the CAN bus with
the load-limit regulator energizing either proportional valve Y207a for opening of the shears or
Y207b for closing of the shears.
The control spool performs a corresponding
stroke. Its control edge opens and the oil flows to
the shears.
The load pressure building up during operation of
the shears gets through the load-pressure tap into
the PLS channel. The load pressure passes
through the orifice to the pressure compensator.
The pressure compensator and the opening cross
section in the control spool ensure a load-pressure-independent discharge flow controlling the
shears.
Sensor B239 is necessary for calibration purposes.

The oil from pump 2 must flow through the pressure compensator and the opening cross-section
at the control edge to port B7 past the pressurelimiting valve and on to the shears.
The oil returning from the shears flows to hammer
bypass valve (90). The oil flows through ports HR
and A6 to control spool port A7 and through nonreturn valve (7) in the control spool to the tank
channel and back to the hydraulic reservoir.

The hammer by-pass valve is then


closed. Solenoid valve Y39.9 is energized so that the return-flow pressure
from the shears gets into the spring
cavity of the hammer bypass valve.
The hammer bypass is kept closed by
the pressure and the spring forces.

Oil flow during opening of the shears


The oil must flow through the pressure compensator and past the control spool edge and the pressure-limiting valve to port A7. The oil flow gets to
the hammer bypass valve and via port A6 and
port HR to the shears.
Hammer bypass valve (90) is kept closed by the
working pressure of the shears.
The return oil from the shears flows via port B7
and the control spool cross-section back to the
tank channel.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 173

Hammer / shears control spool


Travel direction

2
5
LS
B7.1
B7
P02
PZ
C2
1
B239 sensor
P2
3
4
PLS
LS

A7

T
6

Fig. 2

Legend
P2
Pressure channel pump 2
P02
Pressure channel pump 2
C2
Channel to adjusting control spool
PZ
Regulated pressure from compensator
T
Preloaded tank channel
B7
Hammer pressure / shears closing
B7.1 Frequency switch-over
A7
Pressure port for shears opening
PLS
Load-pressure channel
LS
Load-pressure tap

1
2
3
4
5
6
7

Pressure compensator
Electrical pressure cut-off Y239.2
Shuttle valve
Orifice 0.8 in load-pressure channel
Secondary valve with replenishing function
Secondary valve without replenishing
function
Non-return valve

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 174

HYDRAULICS

WX210 - WX240

Hammer circuit with auxiliary function, e.g. shears

Hammer bypass valve

Fig. 3

Hammer bypass valve (No. 90)

This valve has the following functions


a) with hammer operation:
to direct the retrun oil from the hammer
through hosepipe no.444 directly and nearly
pressureless to the hydraulic reservoir.
b) with shears operation:
to enable pressure oil flow for opening of the
shears. Hosepipe no. 442 at port A6 is connected with hosepipe no. 443 at port HR. The
passage to the hydraulic reservoir is closed.
The valve is composed of a pilot-operated nonreturn valve combined with solenoid valve Y39.9
and upstream restrictor.

Fig. 4

Pressure switch S39.9 ensures monitoring of both


switching positions.
The hammer cannot be activated as long as pressure switch S39.9 is open.

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Electrical circuit diagram, hammer / shears equipment

5 - 175

40000448-en

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 176

HYDRAULICS

WX210 - WX240

SHEARS / CRUSHER CIRCUIT (BOOM ADJUSTING EQUIPMENT)

40000562-en

Schematic diagram

Fig. 1
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Shears or crusher circuit with boom adjusting equipment, description


The description is based on the schematic diagram and the section drawing of the control spool.
The shears circuit is supplied from pump 2.
The shears circuit comprises a pressure compensator.

Neutral
In neutral position of the control spool, the oil from
pump 2 flows into channel P2 of the control block
and to the pressure compensator.

5 - 177

The control spool performs a corresponding


stroke. Its control edge opens and the oil flows to
the shears.
The load pressure building up during operation of
the shears gets through the load-pressure tap into
the PLS channel. The load pressure passes
through the orifice to the pressure compensator.
The pressure compensator and the opening cross
section in the control spool ensure a load-pressure-independent discharge flow controlling the
shears.
Sensor B239 is necessary for calibration purposes.

The oil also flows through the blanking plate into


the P02 channel and past the shears control spool
into the C2 channel and then via the other control
spools into the tank channel.

Oil flow during closing of the shears

Activating the shears

The oil from pump 2 must flow through the pressure compensator and the opening cross-section
at the control edge to port B7 past the secondary
valve and on to the shears.

To activate the shears, depress the rocker switch.


The control unit permits selection of all 7 power
stages and the shears symbol appears on display.
The shears is operated by means of the pedal.

Controlling the shears with the pedal


The ESX senses the operation and activates solenoid valve Y113 in the pilot control unit for
switching pilot pressure into the circuit. The pilot
pressure gets into the control block via port PV.
The ESX energizes proportional valve Y242 for
pump control and load-sensing pressure is admitted to the regulator of pump 2.

The adjustment of the control spool blocks the


passage from channel P2 to channel C2.

The oil returning from the shears flows through


port A7 and via the control spool back to the hydraulic reservoir.
Oil flow during opening of the shears

The oil flows through the pressure compensator


and past the control edge of the spool to port A7
and then to the shears. A secondary valve for
pressure protection is provided.
The return oil from the shears flows via port B7 and the control
spool back to the hydraulic reservoir.

The ESX transmits a pedal-excursion and direction-dependent


current signal to the CAN bus with the load-limit regulator
energizing either proportional valve Y207a for opening of the
shears or Y207b for closing of the shears.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 178

HYDRAULICS

WX210 - WX240

Shears / crusher control spool

Travel direction

4
T
LS
B7
P02
PZ
C2

1
P2

B239 sensor
3

2
PLS
LS

A7

T
Y207a

Y207b

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 179

Legend
P2

Pressure channel pump 2

Load-sensing pressure tap

P02

Pressure channel pump 2

PLS

Load-sensing channel

C2

Channel to adjusting control spool

Pressure compensator

PZ

Regulated pressure from compensator

Orifice 0.8 in load-pressure channel

Preloaded tank channel

Shuttle valve

B7

Connection for closing of shears

A7

Connection for opening of shears

Secondary valve with replenishing function

Secondary valve without replenishing function

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 180

HYDRAULICS

WX210 - WX240

Electrical circuit diagram, shears equipment

40000446-en

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

This page left blank intentionally

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5 - 181

5 - 182

HYDRAULICS

WX210 - WX240

HYDRAULIC HAMMER CIRCUIT


(MONOBLOCK BOOM EQUIPMENT)

40000563-en

Schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Hydraulic hammer circuit with monoblock


boom equipment, description
The description is based on the schematic diagram and the section drawing of the control spool.
The circuit of the hydraulic hammer is supplied
from pump 2. The hammer circuit comprises a
pressure compensator and an electrically operated pressure cut-off function.

Neutral
In neutral position of the control spool, the oil from
pump 2 flows into channel P2 of the control block
and to the pressure compensator.
The oil also flows through the blanking plate into
the P02 channel, past the hammer control spool
and then via the other control spools into the tank
channel.

Activating the hammer


To activate the hammer, depress the rocker
switch. The control unit activates power stages 6
or 7, the pedal is switched over to hammer operation (if installed) and the hammer symbol appears
on display together with a number representing
the selected hammer performance level.

Starting hammer operation with joystick


pushbutton or pedal (if installed)
The ESX detects the hammer operation and
switches on solenoid valve Y113 in the pilotcontrol unit so that pilot pressure gets to the control block via port PV.
The ESX energizes proportional valves Y241 and
Y242 for pump control and load-sensing pressure
is admitted to both pump regulators.
INFO: Pump 1 requires load-sensing pressure for
the cooling circuit.
If the pushbutton for continuous hammer operation is pressed, the ESX energizes propotional
valve Y206a, whereby the control spool performs
its maximum downward stroke.

5 - 183

When the hammer is controlled by means of the


pedal, proportional valve Y206a receives partial
flows displacing the control spool downwards in
proportion to pedal excursion.
The load pressure building up during hammer
operation gets through the load-pressure tap in
the control spool into the PLS channel. The load
pressure passes through orifice 0.8 to the pressure compensator and to the electrical pressure
cut-off valve Y239.2.

Performance setting
The hammer pressures preselected on the display
unit influence the electrical pressure cut-off valve
Y239.2 in such a way that the different currents
limit the load-sensing pressures accordingly. This
means that the pressure compensator is fed with
presettable LS pressures so that it can make predefined regulated pressures available to the PZ
channel (bridging channel) and the control spool.
The discharge flows preselected on the display
unit are transmitted by the ESX to proportional
valve Y206a. The resulting pilot pressures produce variable control spool strokes and opening
cross sections at the control spool edges.
At the same time, the ESX transmits the corresponding current signal to proportional valve Y242
so that pump 2 can meet the oil demands.
The LS pressure signal is also transmitted to sensor B239 at the MS port. The current signal from
the sensor is evaluated by the ESX and used for
monitoring of the LS pressure. The ESX responds
to a pressure drop in the LS channel by increasing
the control current to proportional valve Y242 so
that pump 2 delivers a higher discharge flow.

Oil flow
The oil flows through the opening cross-section in
the control spool to port B6 and then to the hydraulic hammer.
The oil returning from the hammer flows through
the return-flow filter back to the reservoir.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 184

HYDRAULICS

WX210 - WX240

Hydraulic hammer control spool

Travel direction
2

5
T
LS
B6
P02

PZ

C2

B239 sensor
P2
3
4
PLS

A6
5

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 185

Legend
P2

Pressure channel pump 2

PLS

Load-pressure channel

P02

Pressure channel pump 2

MS

Connection for sensor B239

C2

Channel to stick control spool

Pressure compensator

PZ

Regulated pressure from compensator

Electrical pressure cut-off Y239.2

Preloaded tank channel

Shuttle valve

B6

Hammer pressure port

Orifice 0.8 in LS channel

A6

closed

Plug

LS

Load-pressure tap

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 186

HYDRAULICS

WX210 - WX240

Electrical circuit diagram, hammer equipment

40000445-en

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 187

5 - 188

HYDRAULICS

WX210 - WX240

HAMMER CIRCUIT WITH AUXILIARY FUNCTION,


MONOBLOCK EQUIPMENT
Schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000564-en

WX210 - WX240

HYDRAULICS

Hammer circuit with auxiliary function like


shears or crusher with monoblock equipment, description
The description is based on the schematic diagram and the section drawing of the control spool.
The circuit is supplied from pump 2. The hammer
circuit comprises a pressure compensator combined with an electrical pressure cut-off function.
For shears operation, only the compensator is
used.

Neutral
In neutral position of the control spool, the oil from
pump 2 flows through channel P2 to the pressure
compensator and then into channel P02 past the
hammer/shears control spool and via the other
control spools to the tank channel.

Activating the hammer


To activate the hammer, depress the rocker
switch. The control unit activates power stages 6
or 7, the pedal is switched over to hammer operation and the hammer symbol appears on display
together with a number representing the selected
hammer performance level. Solenoid valve Y39.9
moreover connects the hammer return line automatically with the hydraulic reservoir.

Starting the hammer operation with joystick pushbutton or pedal


The ESX detects the hammer operation and
switches on solenoid valve Y113 in the pilotcontrol unit so that pilot pressure gets to the control block via port PV.
The ESX energizes proportional valves Y241 and
Y242 for pump control and load-sensing pressure
is admitted to both pump regulators
IMPORTANT: Pump 1 needs load-sensing pressure to supply the cooling circuit.
If the pushbutton for continuous hammer operation is pressed, the ESX control current flows to
proportional valve Y206a, whereby the control
spool performs its maximum downward stroke.
When the hammer is controlled by means of the
pedal, proportional valve Y206a receives partial
flows displacing the control spool downwards in
proportion to pedal excursion.

5 - 189

The load pressure building up during hammer


operation gets through the load-pressure tap in
the control spool into the PLS channel. The load
pressure passes through orifice 0.8 to the pressure compensator and to the electrical pressure
cut-off valve Y239.2.

Performance setting
The hammer pressures preselected on the display
unit influence the electrical pressure cut-off valve
Y239.2 via the ESX in such a way that the different currents limit the load-sensing pressures accordingly. This means that the pressure compensator is fed with presettable LS pressures so that
it can make predefined regulated pressures available to the PZ channel (bridging channel) and the
control spool.
The discharge flows preselected on the display
unit are transmitted by the ESX to proportional
valve Y206a. The resulting pilot pressures produce variable control spool strokes and opening
cross sections at the control spool edges.
At the same time, the ESX transmits the corresponding current signal to proportional valve Y242
so that pump 2 can meet the oil demands.
The LS pressure signal is also transmitted to sensor B239 at the MS port. The current signal from
the sensor is evaluated by the ESX and used for
monitoring of the LS pressure. The ESX responds
to a pressure drop in the LS channel by increasing
the control current to proportional valve Y242 so
that pump 2 delivers a higher discharge flow.

Oil flow
The oil flows through the opening cross-section in
the control spool to port B6 and then to the hydraulic hammer.
The oil returning from the hammer flows to hammer by-pass valve (90) port HR, through the unlocked non-return valve and via port C to the return-flow filter in the hydraulic reservoir.
The non-return valve in control spool (7) prevents
the tank channel preloading pressure from escaping through hammer by-pass valve (90). For the
same reason, the pressure-limiting valve at port
A6 is not equipped with a replenishing non-retrun
valve.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 190

HYDRAULICS

WX210 - WX240

Activating the shears

Oil flow during closing of the shears

To activate, depress the rocker switch. The control permits selection of all available performance
levels and the shears symbol appears on display.

The adjustment of the control spool blocks the


passage from channel P2 to channel C2.

Moreover, solenoid valve Y39.9 in hammer bypass valve (90) is activated electrically.

Operating the shears with the pedal


The ESX senses the operation and activates solenoid valve Y113 in the pilot control unit for
switching pilot pressure into the circuit. The pilot
pressure gets into the control block via port PV.
The ESX energizes proportional valve Y242 for
pump control and load-sensing pressure is admitted to the regulators of pump 2.
The ESX transmits a current signal to proportional
valve Y206a for opening of the shears or Y206b
for closing of the shears.
The control spool performs a corresponding
stroke. Its control edge opens and the oil flows to
the shears.
The load pressure building up during operation of
the shears gets through the load-pressure tap into
the PLS channel. The load pressure passes
through the orifice to the pressure compensator.
The pressure compensator and the opening cross
section in the control spool ensure a load-pressure-independent discharge flow controlling the
shears.
Sensor B239 is necessary for calibration purposes.

The oil from pump 2 must flow through the pressure compensator and the opening cross-section
at the control edge to port B6 past the secondary
valve and on to the shears.
Operating the shears by precision control only
leaves a residual flow of oil.
The residual oil flows through the reflief valve to
the other cylinders.
The oil returning from the shears flows to hammer
bypass valve (90). The oil flows through ports HR
and A6 to control spool port A6 and through nonreturn valve (7) in the control spool to the tank
channel and back to the hydraulic reservoir.
The hammer by-pass valve is then
closed. Solenoid valve Y39.9 is energized so that the return-flow pressure from the shears gets into the
spring cavity of the hammer bypass
valve. The hammer bypass is kept
closed by the pressure and the
spring forces.

Oil flow during opening of the shears


The oil must flow through the pressure compensator and past the control edge of the spool to port
A6. A secondary valve for pressure protection is
provided. As hammer bypass (90) to the tank is
closed, the oil must flow via ports A6 and HR to
the shears.
The return oil from the shears flows via port B6
and the control spool cross-section back to the
tank channel.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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5 - 191

5 - 192

HYDRAULICS

WX210 - WX240

Hammer / shears control spool

Travel direction

2
5
LS

B6
P02
PZ
C2
1
B239 sensor
P2
3
4
PLS
LS

A6

T
6

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 193

Legend
P2

Pressure channel pump 2

Pressure compensator

P02

Pressure channel pump 2

Electrical pressure cut-off Y239.2

C2

Channel to adjusting control spool

Shuttle valve

PZ

Regulated pressure from compensator

Orifice 0.8 in load-pressure channel

Preloaded tank channel

B6

Hammer pressure / shears closing

Secondary valve with replenishing


function

A6

Shears opening

LS

Load-pressure tap

Secondary valve without replenishing


function

PLS

Load-pressure channel

Non-return valve

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 194

HYDRAULICS

WX210 - WX240

Hammer circuit with auxiliary function, e.g. shears with monoblock equipment

Hammer bypass valve

Fig. 4

Hammer bypass valve (No. 90)

This valve has the following functions


c) with hammer operation:
to direct the retrun oil from the hammer
through hosepipe no.444 directly and nearly
pressureless to the hydraulic reservoir.
d) with shears operation:
to enable pressure oil flow for opening of the
shears. Hosepipe no. 442 at port A6 is connected with hosepipe no. 443 at port HR. The
passage to the hydraulic reservoir is closed.
The valve is composed of a pilot-operated nonreturn valve combined with solenoid valve Y39.9
and upstream restrictor.

Fig. 5

Pressure switch S39.9 ensures monitoring of both


switching positions.
The hammer cannot be activated as long as pressure switch S39.9 is open.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Electrical circuit diagram, hammer / shears equipment

5 - 195

40000448-en

Fig. 4

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 196

HYDRAULICS

WX210 - WX240

SHEARS / CRUSHER CIRCUIT, MONO BOOM EQUIPMENT

40000565-en

Schematic diagram

Fig. 1
Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Shears or crusher circuit with monoblock


boom equipment, description
The description is based on the schematic diagram and the section drawing of the control spool.
The circuit of the shears is supplied from pump 2.
The shears circuit comprises a pressure compensator.

5 - 197

The load pressure building up during operation of


the shears gets through the load-pressure tap into
the PLS channel. The load pressure passes
through the orifice to the pressure compensator.
The pressure compensator and the opening cross
section in the control spool ensure a load-pressure-independent discharge flow controlling the
shears.
Sensor B239 is necessary for calibration purposes.

Neutral
In neutral position of the control spool, the oil from
pump 2 flows into channel P2 of the control block
and to the pressure compensator.
The oil also flows through the blanking plate into
the P02 channel and past the shears control spool
into the C2 channel and then via the other control
spools into the tank channel.

Activating the shears


To activate the shears, depress the rocker switch.
The control unit permits selection of all 7 power
stages and the shears symbol appears on display.
The shears is operated by means of the pedal.

Oil flow during closing of the shears


The adjustment of the control spool blocks the
passage from channel P02 to channel C2.
The oil from pump 2 must flow through the pressure compensator and the opening cross-section
at the control edge to port B6 past the secondary
valve and on to the shears.
Operating the shears by precision control only
leaves a residual flow of oil.
The residual oil flows through the reflief valve to
the other cylinders.

Starting shears operation with pedal

Oil flow during opening of the shears

The ESX senses the operation and activates solenoid valve Y113 in the pilot control unit for
switching pilot pressure into the circuit. The pilot
pressure gets into the control block via port PV.

The oil must flow through the pressure compensator and past the control edge of the spool to
port A6. A secondary valve for pressure protection
is provided.

The ESX energizes proportional valve Y242 for


pump control and load-sensing pressure is admitted to the regulator of pump 2.
The ESX energizes either proportional valve
Y206a for opening of the shears or to Y206b for
closing of the shears.
The control spool performs a corresponding
stroke. Its control edge opens and the oil flows to
the shears.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 198

HYDRAULICS

WX210 - WX240

Shears / crusher control spool


Travel direction

T
LS
B6
P02
PZ
C2

1
P2

B239 sensor
3

2
PLS
LS

A6

T
Y206a

Y206b
Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 199

Legend
P2

Pressure channel pump 2

LS

Load-sensing pressure tap

P02

Pressure channel pump 2

PLS

Load-sensing channel

C2

Channel to stick control spool

Pressure compensator

PZ

Regulated pressure from compensator

Orifice 0.8 in load-pressure channel

Preloaded tank channel

Shuttle valve

B6

Connection for closing of shears

Secondary valve

A6

Connection for opening of shears

Secondary valve

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 200

HYDRAULICS

WX210 - WX240

Electrical circuit diagram, shears equipment

40000446-en

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

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5 - 201

5 - 202

HYDRAULICS

WX210 - WX240

SLEWING SYSTEM
Schematic diagram

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000457-en

WX210 - WX240

HYDRAULICS

Connections
A, B

Working connections

MA,MB High-pressure measuring points


MH

High-pressure measuring point

Suction port, feed pump

FS

closed

FE

closed

The oil temperature in the slewing system is limited


by fresh oil from the feed circuit on the one hand
and by transverse flushing of the slewing oil motor
on the other hand.
The admission of fresh oil via a feeding non-return
valve depends on the amount of leakage on the
high pressure side.
The oil motor transverse flushing is generated by
the presure differential in both lines on the oil motor housing.
A control unit for variation of the discharge flow is
provided directly on the adjusting cylinder.

Fa,Fa1 closed
G

Feed-pressure measuring point

PS

Pilot pressure, orifice 1.4 mm

X1, X2 Control pressure measuring points

X3, X4 Adjusting cavity pressure measuring


points
T, R

5 - 203

Tank resp. return

Description
The slewing circuit is a closed circuit. It consists
mainly of the slewing pump (4) and the slewing oil
motor attached to the slewing gearbox (15).
Filling of the closed circuit requires an auxiliary or
feed circuit. The feed circuit is supplied from the
integrated feed pump. The pressure is limited by
the feed-pressure valve.
This pressure is available via two feeding nonreturn valves to the closed circuit for filling purposes. It compensates the leakage oil losses generated on the high-pressure side. Feeding takes
place on the low-pressure side of the closed system.
The slewing high pressure and thus the slewing
torque are limited on both sides by a pressure cutoff valve.
The closed circuit is protected against inadmissibly
high pressure peaks by high-pressure safety
valves called secondary valves.

After engine start, the pilot pressure is available at


the pilot-control unit (60).
On actuation of a slewing movement direction, the
ESX switches on solenoid valve Y113 and the pilot
pressure is admitted through the orifice 1.4 to
port PS of the control unit.
The slewing movement is controlled by means of
the joystick which transmits electrical signals to the
ESX. The ESX is moreover informed of whether
the slewing power limitation is on and which power
level is preset. The ESX evaluates these signals
and energizes the corresponding pressure-control
valve in the control unit.
The slewing angle sensor B213 senses the angle
of the swashplate and thus the actual discharge
flow of the pump (Vgactual) and transmits the value
as a voltage signal to the ESX.
The joystick excursion preselects the desired discharge flow of the pump (Vg reference).
During the acceleration phase of the superstructure, the joystick preselects a higher discharge
flow. As long as there is a difference between
Vg actual and Vg reference, the controller in the ESX
increases the control current to the pressurecontrol valve until the actual discharge volume
(Vg actual) corresponds to the discharge flow preselected by the joysticks (Vg reference).
During deceleration, the control works in the opposite direction.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 204

HYDRAULICS

WX210 - WX240

Slewing pump A 4 VG 71 DE4D (No. 4)

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000458-en

WX210 - WX240

HYDRAULICS

5 - 205

Fig. 2

Legend
A

Working connection

12

Bearing

Working connection

13

Valve plate

Drive shaft

14

Feed pump

Shaft seal

15

Feed-pressure limiting valve

Bearing

16

Secondary valve

Roller bearing

17

Secondary valve

Swash-plate

18

Pressure cut-off

Slipper pad

19

Control unit

Axial piston

20

Pressure-control valve Y209

Cylinder block

21

Pressure-control valve Y212

Cup springs

22

Replenishing valves

10

Helical spring

23

Adjusting cylinder

11

Angle plate

24

Slewing angle sensor B213

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 206

HYDRAULICS

WX210 - WX240

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 207

Description
The slewing pump is an axial piston pump in
swash-plate design for closed hydraulic circuits.
The discharge flow rises in proportion to the tilting
angle of the swash-plate from zero to maximum.
When the swash-plate crosses zero position, the
discharge flow changes its direction without jerk.
To protect the drive system, the pump is equipped
with high-pressure safety valves (called secondary
valves). These valves comprise also so-called
feeding non-return valves. An integrated auxiliary
pump (called feed pump) ensures that the closed
circuit is always kept filled.
A control mechanism receiving its control instructions from the ESX and the joystick actuates the
adjusting cylinder which varies the tilting angle and
direction of the swash-plate. The maximum pressure is limited by the pressure cut-off.
When the pump is turning, drive shaft (1) drives
cylinder block (8) and feed pump (12). Cylinder
block (8) is interlocked with the drive shaft. The
block has cylinder bores in which the axial pistons
(7) work. The axial piston takes support on the
swash-plate (5) via slipper pads (6). The friction
surfaces of the slipper pads on the swash-plate
and on the ball sockets are lubricated by pressure
oil which gets through a central bore in the axial
piston to the ball socket and through another bore
below the slipper pad.
To achieve sufficient tightness in the low-pressure
range, cylinder block (8) is pressed by cup spring
assembly (9) and helical spring (10) against angle
plate (11).

The angle plate is positioned with positioning


screw (15). The positioning screw is equipped with
a cam engageing in a groove of the angle plate.
Positioning achieved by cam adjustment of the
angle plate permits a variation of the slewing pump
characteristics. Positioning of the angle plate
changes the influence of the high-pressureinduced resetting forces acting on the angle plate
(5).
The drive shaft (1) drives the feed pump (14) with
its shaft end. For pressure limiting in the feed circuit, a feed-pressure limiting valve (15) is provided.
The valve plate (13) contains the secondary valves
for right / left slewing (16+17) with their integrated
feeding non-return valves.
The pressure cut-off (18) limits the high pressure
and thus the slewing torque for both slewing directions. A shuttle valve in the circuit directs the slewing high pressure towards the metering piston of
the pressure cut-off.
The control unit (19) with the pressure-control
valves (20) and the replenishing valves (21) is
used for swash-plate adjustment. The pressurecontrol valves (20) are energized by the ESX.
The pilot pressure is available via port PS with a
metering orifice of 1.4 mm at both pressurecontrol valves and at the pressure cut-off. Orifice
1.4 is necessary for protection of the pressure
cut-off against the external pressure.
During slewing, a pressure-control valve is activated so that the pilot pressure gets into the adjusting cavity of adjusting cylinder (22) as control
pressure. The adjusting piston performs a stroke
and the swash-plate angle (5) is changed. During
deceleration of the superstructure, the adjusting
cylinder (22) is reset by spring force and a replenishing valve (21) ensures filling of the increased
cavity volume.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 208

HYDRAULICS

WX210 - WX240

Port valve plate of slewing pump A4 VG 56 DE4D

40000567-en

Fig. 1

Legend
1

Port plate

Feed-pressure valve, fixed setting

Secondary valve, fixed setting

Pressure cut-off, adjustable

1
Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 209

Port valve plate of slewing pump A 4 VG 71 DE4D

3
2

Fig. 3

Legend
1
1

Port plate

Feed-pressure valve, adjustable

Secondary valves, adjustable

Pressure cut-off, adjustable

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 210

HYDRAULICS

WX210 - WX240

Slewing pump valves


Feed-pressure limiting valve (No. 15)

40000566-en

Sekundrventil

Fig. 4

Legend
P
M
G
1
2
3

Feed pressure
Metering surface
Housing / tank
Valve piston
Spring
Spring plate

Description
The feed-pressure limiting valve limits the pressure
of the integrated auxiliary pump. This valve is a
directly controlled pressure limiting valve with
surge-damping.
Feed pressure P acts on the metering surface M
via the tapered section of the piston.
The hydraulic force opposing the spring force is
generated here.
In operation, the feed pump fills the feeding circuit.
Excess oil flows past the opened valve piston into
the housing and returns through the tank line. The
existing feed pressure remains constant.

Fig. 5

HD
1
2
3
4
5
6

High pressure
Spring plate
Spindle
High-pressure spring
Spring plate, adjustable
Safety screw
Feed spring

Description
The secondary valve fulfills two functions in the
closed slewing circuit. It protects against pressure
peaks and ensures filling of the system.
The system has one valve for each slewing direction. Filling of the system (also called feeding) always takes place automatically on the side without
high pressure. The force of the feed pressure lifts
the entire spring assembly (1 5) against the
spring (6) with the high-pressure side being supplied with oil.
The high pressure gets into the spring cavity between the spring plates and through a gap also
into the spring cavity of the feed spring (6) where
the downward hydraulic force opposing the force of
high-pressure spring (3) is generated.
An inadmissibly high pressure peak pushes spring
plate (4) with spindle (2) downwards against spring
(3). The conical section at the end of spindle (2) is
lifted off its seat. The pressure peak escapes
against the feed pressure through the second secondary valve to the low-pressure side.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

Pressure cut-off valve (No. 18)

HYDRAULICS

5 - 211

Description
The pressure cut-off valve limits the slewing high
pressure by way of control pressure regulation.
The shuttle valve (1) ensures this function for both
slewing directions.
High pressure prevailing on one side pushes highpressure piston (2) against control piston (3) and
spring (5). If the hydraulic force below piston (2) is
greater, control piston (3) with its control edge is
lifted. The control pressure flows into the housing
until the high pressure diminishes again. The force
of spring (5) now displaces control piston (3)
downwards and the control edge is closed again.
This results in a regulation of control pressure pSt
which determines the slewing high pressure and in
which the force of the high pressure below piston
(2) is compared to the spring force.
Rising high pressure reduces the control pressure
and vice versa.
The spring force can be adjusted with setscrew (7).

Fig. 6

Legend
pSt

Control pressure

Housing / tank

HD-A

High pressure, side A

HD-B

High pressure, side B

Shuttle valve

High-pressure piston

Control piston

Spring plate

Spring

Spring plate

Setscrew

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 212

HYDRAULICS

WX210 - WX240

Feed-pressure limiting valve of slewing pump A 4 VG 71 DE4D

pS9

40000568-en

The feed-pressure limiting valve limits the pressure of the integrated auxiliary pump. This valve is
a directly controlled pressure limiting valve with
surge-damping.
Feed pressure pSp acts on the metering surface
M via the tapered section of the piston. The hydraulic force opposing the spring force is generated here.

M
2

Fig. 1

Legend
pSp

Speisedruck

Metering surface

Housing / tank

Valve piston

Spring

Spring plate

Setscrew

The force of spring (2) is adjustable with setscrew


(4).
In operation, the feed pump fills the feeding circuit. Excess oil flows past the opened valve piston
into the housing and returns through the tank line.
The existing feed pressure remains constant.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 213

Secondary valve of slewing pump A 4


VG 71 DE4D
The secondary valve fulfills two functions in the
closed slewing circuit. It protects against pressure
peaks and ensures filling of the system.

The system has one valve for each slewing direction.


The valve is moreover equipped with a bypass
function.

Filling of the system (also called feeding) always


takes place automatically on the side without high
pressure. The force of the feed pressure lifts the
entire spring assembly (1 5) against the spring
(6) with the high-pressure side being supplied with
oil.

4
5
3

The high pressure gets into the spring cavity between the spring plates and through a gap also
into the spring cavity of the feed spring (6) where
the downward hydraulic force opposing the force of
the high-pressure spring is generated.
An inadmissibly high pressure peak pushes spring
plate (4) with spindle (2) downwards against spring
(3). The conical section at the end of spindle (2) is
lifted off its seat. The pressure peak escapes
against the feed pressure through the second secondary valve to the low-pressure side.
The bypass function of the valve is inoperational
for use in the excavator. For this purpose, screw
(7) must be turned counterclockwise to the limit
stop and secured.

2
pHD
1

pSp
Fig. 2

Legend
pHD

High pressure

pSp

Feed pressure

Spring plate

Spindle

High-pressure spring

Spring plate, adjustable

Safety screw

Feed spring

Bypass screw

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 214

HYDRAULICS

WX210 - WX240

Slewing pump control unit

40000569-en

Fig. 6

Legend
1

Valve housing

Slewing direction:

Pressure-control valve Y209, left

Pressure-control valve Y212, right

Replenishing valves, 2 units

Plug

Adjusting cylinder

Adjusting cavity, slewing to the left

Adjusting cavity, slewing to the right

Housing, tank

Y209

Y212

WX210

left

right

WX240

right

left

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 215

Description

Slewing

The control unit serves the purpose of adjusting


the swash-plate position and thus the discharge
flow.

When the joystick is actuated, the ESX activates


solenoid valve Y113 even before the movement
starts and the pilot pressure passes through the
orifice of 1.4 in port PS to the pressure-control
valves Y209 and Y212.

Valve housing (1) contains pressure-control valves


(2+3) and replenishing valves (4) for both slewing
directions.
The pressure-control valves convert ESX control
current into control pressure.
The replenishing valves (4) ensure filling of the
adjusting cavities after slewing.

Neutral
In neutral position, the control unit is without pilot
pressure.
The cavities of the adjusting cylinders (6) are pressure-relieved via the pressure-control valves (2+3)
towards the housing (9). The swash-plate is in zero
position.

The control current from the ESX flows to one of


the pressure-control valves so that control pressure is admitted to one of the adjusting cavities.
The oil from the opposite cavity can flow via the
second pressure-control valve to the housing.
After setting the joystick back to neutral, the pilot
pressure supply is shut off. The adjusting cylinder
and the swash-plate are reset by the control pressure drop and the spring forces. The cavity with its
now increased volume sucks in oil from housing
(9) via replenishing valve (4).

Braking
The braking effect can be preselected in three
steps by means of the corresponding key.
The ESX reduces its the control current to the
pressure-control valves correspondingly so that
three significantly different braking effects are obtained.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 216

HYDRAULICS

Pressure-control valve

WX210 - WX240

Description
The pressure-control valve consists basically of a
solenoid actuating a control piston. The PWM signals from the ESX are converted proportionally into
control pressure.
Without current, the adjusting cavity is connected
via the control piston pressureless to the housing.
A control current generates the electrical force
which displaces the control piston downwards
against the spring. The connection to the housing
is interrupted and the pilot pressure gets via the
opening cross-section into the adjusting cavity.
The pressure building up in the cavity depends on
the intensity of the control current. When the control current decreases, the spring pushes the control piston back upwards and the flow cross-section
diminishes.

Fig. 7

Legend
1

Valve housing

Solenoid

Electrical connection

Control piston

Spring

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 217

Slewing gearbox assembly (No. 15)

40000573-de

Fig. 1

Legende
1

Slewing gearbox S10

Oil motor

Speed sensor B35.2

Oil level indicator expansion tank

Oil draining line

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 218

HYDRAULICS

WX210 - WX240

Slewing gearbox (No. 15)

Fig. 2

The slewing gearbox is a two-stage planetary


gearbox engageing in the ball-bearing slewing
ring.
The gearbox is designed in such a way that the
slewing movement is started and braked by the
axial-piston motor.
The output shaft of the axial-piston motor drives
the sun wheel of the first planetary stage. The
planetary wheels are in mesh with the toothing of
the housing. The planetary carrier of the first
stage drives the sun wheel of the second stage.

The planetary gears of the second stage are also


in mesh with the housing toothing. The planetary
carrier of the second stage drives the pinion shaft.
The pinion engages in the toothing of the slewing
ring.
The slewing oil motor is an axial-piston unit with
constant displacement.
The output speed is proportional to the inflowing
discharge oil. The torque supplied increases with
the pressure differential between high-pressure
and low-pressure side.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Oil motor
The oil motor is an axial-piston unit with constant
displacement. The output speed is proportional to
the inflowing discharge flow from the slewing
pump.
The torque supplied increases with the pressure
differential between high-pressure and low-pressure side.
The oil motor is operated with transverse flushing
for cooling reasons.
The different pressure levels building up during
the work in connected tank lines T1 and T2 lead
to an oil flow carrying away the heat towards the
tank.

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 219

5 - 220

HYDRAULICS

WX210 - WX240

Speed sensor B35.2


The sensor is composed of two Hall-effect elements for speed and sense-of-rotation detection.
The frequency signals are phase-shifted by 90,
i.e. that for a supposed rotation to the right frequency signal f2 is phase-shifted by approx. 90
with respect to frequency f1. See timing diagram
below.
The frequencies are evaluated by the ESX.
In the event of sensor failure, a fault message is
issued and the brake applied 3 seconds later.

Timing diagram
Fig. 5

Description

Fig. 7

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

Integrated holding brake

5 - 221

By the press of a key, the driver can choose


among several modes of operation for the brake:

Brake applied
Solenoid valve Y35 is then without current and the
brake is depressurized to the tank

Brake permanently released


Solenoid valve Y35 is energized by the ESX. In
this case, pilot pressure is admitted to the brake.

Brake in automatic mode of operation


In the automatic mode, the holding brake is released when slewing is initiated and applied automatically when the superstructure is stationary.

Fig. 4

The excursion of the joystick is sensed by the


ESX.

Legend

The ESX switches on solenoid valve Y35.

Housing

Oil motor

Oil motor output shaft

Hub

Brake disks

Brake piston

Springs

Pressure compartment

The slewing movement is detected by speed sensor B35.2 in the slewing oil motor.
When the joystick is brought back to neutral, the
superstructure slows down depending on the preselected braking effect until it is stationary. The
stop condition is detected by speed sensor B35.2
and the ESX shuts off solenoid valve Y35. The
braking pressure escapes via solenoid valve Y35
to the tank and the brake is applied by spring
force.

A multi-disk brake integrated in the slewing gearbox is used as superstructure holding brake. The
brake works in accordance with the spring brake
principle, i.e. the brake is applied by spring force
when no pilot pressure is available. When pilot
pressure is applied, the brake piston compresses
the springs so that the disks are free to turn.
When the pilot control is shut off in the driver's cab,
the brake is applied automatically for safety reasons.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 222

HYDRAULICS

WX210 - WX240

GRAB ROTATION MECHANISM

40000461-en

Schematic diagram

Fig. 1

Description
By means of the grab rotation mechanism, a
clamshell grab can be rotated in any direction, for
instance, for the excavation of trenches or shafts.
The system can also be used for positioning a
trenching backhoe or for adjusting the positioning
movements of other attachments.
The oil is directed by one of the pumps of twin
gear pump (230) to solenoid valve (231). This
solenoid has an open zero position so that the oil
can flow back pressureless to the tank. The solenoid valves is equipped with two magnet coils.

When one direction or the other is selected, the


control piston is displaced by either solenoid
Y37.1 or Y37.2 and the oil flows forwards through
the express coupling to grab rotation motor (232)
or alternative attachments.
The pressure in the system is limited by an adjustable pressure-limiting valve in the connection
block of the solenoid valve.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

HYDRAULICS

5 - 223

Solenoid valve for grab rotation (No. 231)

Fig.2

Legend

Description

Pump connection

Tank connection

Working connection

Working connection

Blanking plate

Direct-controlled pressure-limiting
valve, adjustable

Double solenoid valve Y 37.1 and Y 37.2

The solenoid valve is used for grab positioning


movements by controlling the grab rotation motor.
It consists of a blanking plate with integrated pressure-limiting valve as primary valve for pump
pressure. The valve is adjustable.
The control piston of the double solenoid valve
has an open zero position to ensure that there is
no pressure build-up after the system is put into
operation and that the power demands remain
low. After activation of a solenoid, the control piston is displaced correspondingly by magnetic
force so that the pressure fluid must flow to the
respective working connection and to the oil motor. The return from the oil motor is connected via
the control piston to the tank.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

5 - 224

HYDRAULICS

WX210 - WX240

Fig.3

Legend
A

Working connection

Working connection

Direct-controlled secondary valves

Replenishing valves

The grab rotation motor is a slow-turning hydraulic


motor working in accordance with the Gerotor principle.
The motor has to turn the grab with its clamshells
so that material can be picked up and deposited
with high precision. The shaft of the rotation motor
drives a pinion engageing a gear ring.
External forces acting on the rotation motor are
limited on both sides by secondary valves. An inadmissibly high pressure opens one of these
valves and the pressure peak is directed to the
low-pressure side. Oil shortages are avoided by
replenishing valves on both sides.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

Service manual
Section 6 Troubleshooting and Repair
WX210 - WX240

9-91270

6-2

TROUBLESHOOTING AND REPAIR

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6-3

6-4

TROUBLESHOOTING AND REPAIR

WX210 - WX240

Table of contents

FAULT CODES ............................................................................................... 6


General information on fault codes .............................................................................................. 6
Fault codes ...................................................................................................................................... 8
Fault codes PCS unit .................................................................................................................... 20
Fault codes, Central Unit.............................................................................................................. 21

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6-5

6-6

TROUBLESHOOTING AND REPAIR

WX210 - WX240

FAULT CODES

40000572-en

General information on fault codes


The following units of the machine are permanently
monitored:
- Central Unit

(CU)

- Power-Control-System

(PCS)

- Electro-Hydraulic Controller

(ESX)

- Multi-function display
In the event of a fault, a fault code (e.g. N7004)
is diplayed in the upper half of the multi-function
display (108, Fig. 1) in combination with two coloured warning lights (112 yellow and 113 red,
Fig. 1) which will light up individually or together,
depending on the type of fault. Depending on the
severity of the fault, a special tone signal will be
heard in addition.
Meaning of signals:
RED

Severe fault

The safety of persons and/or the


CONTINUOUS functioning of essential units of
the machine is at risk.
TONE

Fig. 1

In addition to the fault code, the lower half of the


multi-function display (108, Fig. 1) gives an explanation of the fault code (error text).
In individual cases there is the possibility of several
faults occurring at the same time.
The corresponding error codes are then displayed
one after another in alternation with the normal
display contents.

Severe faults must be rectified


immediately.
Shut off the machine at once.

YELLOW

The fault signalled is not relevant


to the safety of persons or to the
functioning of the machine.

These faults must be rectified as

SINGLE BEEP fast as possible. In most of the

cases, however, the machine remains fully functional.

(see also "Multi-function display")

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

The following groups of error codes can be displayed:


Group

Unit

7000

Central unit and engine

8000

Power-Control-System

9000

Hydraulics

13000

Multi-function display

These faults can, as a rule, not be rectified by your


own means as they require special tools and special knowledge.
Therefore, note the fault code and inform our Service Dept. accordingly if you cannot rectify the fault
yourself.
Apart from the fault code, the Service Dept. needs
the following information:
- machine type, machine no., possibly also the
engine no.
- part number P/N of the PCS, ESX
- what work was being done when the fault occurred?
- did the machine behave differently from normal
situations?
- which pilot and warning lamps were lit up?
- what else was displayed on the screen?
- what external influences was the machine exposed to (great heat/cold, dust, continuous loading over a long time)?

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6-7

6-8

TROUBLESHOOTING AND REPAIR

WX210 - WX240

Fault codes

40000470-en

9000

(German)

9011

ESX checksum fault

9012

ESX cutoff fault

9013

SPI communication of ESX defective

9014

SPI bus of ESX reserved

9015

Checksum fault on initialization of ESX system monitoring

9016

Plausibility fault on initialization of ESX system monitoring

9017

ESX reset through user watchdog

9018

ESX reset through system watchdog

9019

ESX hardware fault

9020

Checksum fault during readout of ESX fault memory

9021

Fault in reading of ESX fault memory

9022

ESX value outside valid range

9023

Supply voltage of ESX operation amplifier and multiplexer defective

9024

ESX temperature outside permitted range

9025

Processor configuration faulty due to ESX hardware

9026

Multiplexer or ESX A/D converter defective.

9027

Threshold voltage of ESX inputs faulty

9028

ESX frame potential faulty

9029

Supply voltage of ESX watchdog module defective

9030

Frame potential at BTS module of ESX faulty

9031

ESX relay defective

9032

ESX watchdog module cannot switch off relay

9033

ESX watchdog module defective

9034

CPU of ESX defective

9035

ESX flags cannot be set

9036

ESX flags cannot be scanned

9037

ESX arithmetic unit defective

9038

ESX multiplier defective

9039

Fault in CPU test sequence of ESX

9040

External RAM or ROM of ESX defective

9041

Shadow memory module of ESX defective

9042

Net current measurement on start of ESX faulty

9043

Cyclic net current measurement of ESX faulty

9044

Internal RAM defective on start of ESX

9045

Cyclic internal RAM test of ESX defective

9046

Ignition lock input status of ESX faulty

9047

Cyclic diagnosis of ESX faulty

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

9048

Other diagnostic fault at ESX

9055

Read machine information from ESX memory

9056

Read options from ESX memory

9057

Read configuration parameters from ESX memory

9058

Read pump diagram parameters from ESX memory

9059

Read equipment parameters from ESX memory

9060

Read servo control parameters from ESX memory

9061

Read mode parameters from ESX memory

9062

Read control block parameters from ESX memory

9063

Read main pump parameters from ESX memory

9064

Read slewing pump parameters from ESX memory

9065

Read component parameters from ESX memory

9066

Read fault range 1 from ESX memory

9067

Read fault range 2 from ESX memory

9068

Read fault range 3 from ESX memory

9069

Write equipment information into ESX memory

9070

Write options into ESX memory

9071

Write configuration parameters into ESX memory

9072

Write pump diagram parameters into ESX memory

9073

Write equipment parameters into ESX memory

9074

Write servo control parameter into ESX memory

9075

Write mode parameters into ESX memory

9076

Write control block parameters into ESX memory

9077

Write main pump parameters into ESX memory

9078

Write slewing pump parameters into ESX memory

9079

Write component parameters into ESX memory

9080

Write fault range 1 into ESX memory

9081

Write fault range 2 into ESX memory

9082

Write fault range 3 into ESX memory

9083

Read machine settings from ESX memory

9084

Write machine settings into ESX memory

9085

Machine settings contradictory

9086

Machine settings not in admissible range

9087

Read hammer configuration from ESX memory

9088

Write hammer configuration into ESX memory

9089

hammer configuration data contradictory

9090

hammer configuration data not in admissible range

9091

Read milling configuration from ESX memory

9092

Write milling configuration into ESX memory

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6-9

6 - 10

TROUBLESHOOTING AND REPAIR

9093

Milling configuration data contradictory

9094

Milling configuration data not in admissible range

9095

Read slewing range limit from ESX memory

9096

Write slewing range limit into ESX memory

9097

Slewing range limit contradictory

9098

Slewing range limit not in admissible range

9103

Write control block solenoids calibration into ESX memory

9104

Write proportional demand solenoids calibration into ESX memory

9105

Write slewing pump solenoids calibration into ESX memory

9106

Write calibration of pressure relief valve solenoid for attachment into ESX memory

9107

Write analogy input calibration into ESX memory

9108

Write control block calibration into ESX memory

9109

Write proportional demand control calibration into ESX memory

9110

Write slewing pump calibration into ESX memory

9117

Excavator type not initialised

9118

Excavator type: faulty CAN data

9119

Read excavator type from ESX memory

9120

Write excavator type into ESX memory

9121

Excavator type contradictory

9122

Excavator type not in admissible range

9123

Read equipment configuration from ESX memory

9124

Write equipment configuration into ESX memory

9125

Equipment configuration contradictory

9126

Equipment configuration not in admissible range

9127

Read keyboard field status from ESX memory

9128

Write keyboard field status into ESX memory

9129

Keyboard field status contradictory

9130

Keyboard field status not in admissible range

9131

Read optional equipment from ESX memory

9132

Write optional equipment into ESX memory

9135

Read configuration of specific components from ESX memory

9136

Write configuration of specific components into ESX memory

9139

Read software options from ESX memory

9140

Write software options into ESX memory

9141

Read configuration results from ESX memory

9142

Write configuration results into ESX memory

9143

Immobilizer release in ESX not correct

9144

System status not available on start of ESX

9145

Inadmissible change in system status of ESX requested

WX210 - WX240

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

9151

CAN bus No. 1 Bus OFF

9152

CAN bus No. 1 Bus warning

9153

CAN bus No. 1 overrun on transmission

9154

CAN bus No. 1 overrun on reception

9155

CAN bus No. 1 warning on reception

9161

CAN bus No. 2 Bus OFF

9162

CAN bus No. 2 Bus warning

9163

CAN bus No. 2 overrun on transmission

9164

CAN bus No. 2 overrun on reception

9165

CAN bus No. 2 warning on reception

9171

Central electronic unit message CID_CU_SYSTEM failure

9173

Central electronic unit message CID_CU_DEVICE_STATUS failure

9175

Central electronic unit message CID_CU_TIME_STAMP failure

9177

Central electronic unit message CID_CU_ANALOG failure

9181

PCS message CID_PCS_STATUS failure

9183

PCS message CID_PCS_TEMP failure

9185

PCS message CID_PCS_RPM failure

9187

PCS message CID_PCS_IOSTAT failure

9191

Display message CID_C4_STATUS failure

9193

Display message CID_C4_COUNTER failure

9201

Keyboard field 1 status message failure

9203

Keyboard field 2 status message failure

9205

Keyboard field 3 status message failure

9231

Mechanical slewing brake display status fault

9232

Forward travel display status fault

9234

Reverse travel display status fault

9251

Highway travel key not available

9252

Highway travel key not responding

9253

Highway travel key, display fault left LED

9254

Highway travel key, display fault right LED

9261

Slewing brake key not available

9262

Slewing brake key not responding

9263

Slewing brake key, display fault left LED

9264

Slewing brake key, display fault right LED

9266

Overload warning device key not available

9267

Overload warning device key not responding

9268

Overload warning device key, display fault left LED

9269

Overload warning device key, display fault right LED

9271

Slewing delay key not available

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6 - 11

6 - 12

TROUBLESHOOTING AND REPAIR

9272

Slewing delay key not responding

9273

Slewing delay key, display fault left LED

9274

Slewing delay key, display fault right LED

9281

Operating scheme coding plug, cable parting

9282

Operating scheme coding plug, dual short circuit after supply voltage

9283

Operating scheme coding plug not available

9286

Boom adjusting mechanism coding plug, cable parting

9287

Boom adjusting mechanism coding plug, short circuit after supply voltage

9288

Boom adjusting mechanism coding plug not available

9291

Servo control system changeover switch, cable parting

9292

Servo control system changeover switch, short circuit after supply voltage

9293

Servo control system changeover switch not available

9301

Right joystick failure

9302

Right joystick, message counter faulty

9303

Right joystick, CAN communication faulty

9304

Right joystick, initialization message faulty

9305

Right joystick, faulty EEPROM access

9306

Right joystick, inverse message failure

9307

Right joystick, inverse message defective

9308

Right joystick, message counter of inverse message faulty

9309

Right joystick, faulty processor

9310

Right joystick, Alive message failure

9312

Right joystick, pushbutton 1 defective

9313

Right joystick, pushbutton 2 defective

9314

Right joystick, pushbutton 3 defective

9315

Right joystick, pushbutton 4 defective

9316

Right joystick, pushbutton 5 defective

9319

Right joystick, sensor in "X" direction not installed

9320

Right joystick, sensor in "X" direction defective

9321

Right joystick incompatible status in "X" direction

9322

Right joystick, sensor in "Y" direction not installed

9323

Right joystick, sensor in "Y" direction defective

9324

Right joystick incompatible status in "Y" direction

9331

Left joystick, failure

9332

Left joystick, message counter faulty

9333

Left joystick, CAN communication faulty

9334

Left joystick, initialization message faulty

9335

Left joystick, faulty EEPROM access

9336

Left joystick, inverse message failure

WX210 - WX240

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

9337

Left joystick, inverse message defective

9338

Left joystick, message counter of inverse message faulty

9339

Left joystick, faulty processor

9340

Left joystick, Alive message failure

9342

Left joystick, pushbutton 1 defective

9343

Left joystick, pushbutton 2 defective

9344

Left joystick, pushbutton 3 defective

9345

Left joystick, pushbutton 4 defective

9346

Left joystick, pushbutton 5 defective

9349

Left joystick, sensor in "X" direction not installed

9350

Left joystick, sensor in "X" direction defective

9351

Left joystick incompatible status in "X" direction

9352

Left joystick, sensor in "Y" direction not installed

9353

Left joystick, sensor in "Y" direction defective

9354

Left joystick, incompatible status in "Y" direction

9361

Bulldozer master pedal failure

9362

Bulldozer master pedal, message counter faulty

9363

Bulldozer master pedal, CAN communication faulty

9364

Bulldozer master pedal, initialization message faulty

9365

Bulldozer master pedal, faulty EEPROM access

9366

Bulldozer master pedal, inverse message failure

9367

Bulldozer master pedal, inverse message defective

9368

Bulldozer master pedal, message counter of inverse message faulty

9369

Bulldozer master pedal, faulty processor

9370

Bulldozer master pedal, Alive message failure

9379

Sensor of Bulldozer master pedal not installed

9380

Sensor of bulldozer master pedal defective

9381

Incompatible status of bulldozer master pedal

9382

Sensor of 1st slave pedal not installed

9383

Sensor of 1st slave pedal defective

9384

Incompatible status of 1st slave pedal

9385

Sensor of 2nd slave pedal not installed

9386

Sensor of 2nd slave pedal defective

9387

Incompatible status of 2nd slave pedal

9388

Sensor of 3rd slave pedal not installed

9389

Sensor of 3rd slave pedal defective

9390

Incompatible status of 3rd slave pedal

9391

Driving pedal failure

9392

Driving pedal, message counter faulty

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6 - 13

6 - 14

TROUBLESHOOTING AND REPAIR

9393

Driving pedal, CAN communication faulty

9394

Driving pedal, initialization message faulty

9395

Driving pedal, faulty EEPROM access

9396

Driving pedal, inverse message failure

9397

Driving pedal, inverse message defective

9398

Driving pedal, message counter of inverse message faulty

9399

Driving pedal, faulty processor

9400

Driving pedal, Alive message failure

9409

Sensor of driving pedal not installed

9410

Sensor of driving pedal defective

9411

Incompatible status of driving pedal

9412

Sensor of 1st slave pedal not installed

9413

Sensor of 1st slave pedal defective

9414

Incompatible status of 1st slave pedal

9415

Sensor of 2nd slave pedal not installed

9416

Sensor of 2nd slave pedal defective

9417

Incompatible status of 2nd slave pedal

9418

Sensor of 3rd slave pedal not installed

9419

Sensor of 3rd slave pedal defective

9420

Incompatible status of 3rd slave pedal

9421

Auxiliary joystick failure

9422

Auxiliary joystick, message counter faulty

9423

Auxiliary joystick, CAN communication faulty

9424

Auxiliary joystick, initialization message faulty

9425

Auxiliary joystick, faulty EEPROM access

9426

Auxiliary joystick, inverse message failure

9427

Auxiliary joystick, inverse message defective

9428

Auxiliary joystick, message counter of inverse message faulty

9429

Auxiliary joystick, faulty processor

9430

Auxiliary joystick, Alive message failure

9432

Auxiliary joystick, pushbutton 1 defective

9433

Auxiliary joystick, pushbutton 2 defective

9434

Auxiliary joystick, pushbutton 3 defective

9435

Auxiliary joystick, pushbutton 4 defective

9436

Auxiliary joystick, pushbutton 5 defective

9439

Auxiliary joystick, sensor in "X" direction not installed

9440

Auxiliary joystick, sensor in "X" direction defective

9441

Auxiliary joystick, incompatible status in "X" direction

9442

Auxiliary joystick, sensor in "Y" direction not installed

WX210 - WX240

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

9443

Auxiliary joystick, sensor in "Y" direction defective

9444

Auxiliary joystick, incompatible status in "Y" direction

9511

Safety lever, cable parting

9512

Safety lever, short circuit after supply voltage

9513

Safety lever not available

9521

Safety valve, equipment, cable parting

9522

Safety valve, equipment, accidental ground

9523

Safety valve, equipment, short circuit after supply voltage

9524

Safety valve, equipment, defective

9531

Safety valve, driving, cable parting

9532

Safety valve, driving, accidental ground

9533

Safety valve, driving, short circuit after supply voltage

9534

Safety valve, driving, defective

9536

Safety valve, slewing, cable parting

9537

Safety valve, slewing, accidental ground

9538

Safety valve, slewing, short circuit after supply voltage

9539

Safety valve, slewing, defective

9551

Pressure switch, parking brake, defective

9611

Proportional demand valve, pump P1, cable parting

9612

Proportional demand valve, pump P1, accidental ground

9613

Proportional demand valve, pump P1, short circuit after supply voltage

9614

Proportional demand valve, pump P1, control fault

9615

Proportional demand valve, pump P1, defective

9618

Pressure sensor, pump P1, cable parting

9619

Pressure sensor, pump P1, short circuit after supply voltage

9621

Proportional demand valve, pump P2, cable parting

9622

Proportional demand valve, pump P2, accidental ground

9623

Proportional demand valve, pump P2, short circuit after supply voltage

9624

Proportional demand valve, pump P2, control fault

9625

Proportional demand valve, pump P2, defective

9628

Pressure sensor, pump P2, cable parting

9629

Pressure sensor, pump P2, short circuit after supply voltage

9651

Pressure sensor, boom, piston surface, cable parting

9652

Pressure sensor, boom, piston surface, short circuit after supply voltage

9653

Load pressure sensor, cable parting

9654

Load pressure sensor, short circuit after supply voltage

9655

Pressure sensor, driving function, cable parting

9656

Pressure sensor, driving function, short circuit after supply voltage

9711

Left servo-valve, slewing, cable parting

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6 - 15

6 - 16

TROUBLESHOOTING AND REPAIR

9712

Left servo-valve, slewing, accidental ground

9713

Left servo-valve, slewing, short circuit after supply voltage

9714

Left servo-valve, slewing, control fault

9715

Left servo-valve, slewing, defective

9716

Left servo-valve, slewing, flow measurement deviation

9721

Right servo-valve, slewing, cable parting

9722

Right servo-valve, slewing, accidental ground

9723

Right servo-valve, slewing, short circuit after supply voltage

9724

Right servo-valve, slewing, control fault

9725

Right servo-valve, slewing, defective

9726

Right servo-valve, slewing, flow measurement deviation

9731

Valve, mechanical slewing brake, cable parting

9732

Valve, mechanical slewing brake, accidental ground

9733

Valve, mechanical slewing brake, short circuit after supply voltage

9741

Angle sensor, slewing pump, cable parting

9742

Angle sensor, slewing pump, short circuit after supply voltage

9743

Angle sensor, slewing pump, faulty calibration

9744

Angle sensor, slewing pump, faulty sense of rotation

9747

Speed sensor, slewing, accidental ground, input 1

9748

Speed sensor, slewing, accidental ground, input 2

9749

Speed sensor, slewing, short circuit after supply voltage, input 1

9750

Speed sensor, slewing, short circuit after supply voltage, input 2

9751

Speed sensor, slewing, inadequate number of pulses

9753

Speed sensor, slewing, max. admissible frequency exceeded

9754

Speed sensor, slewing, faulty direction evaluation

9755

Speed sensor, slewing, cable parting, input 1

9756

Speed sensor, slewing, cable parting, input 2

9757

Speed sensor, slewing, faulty sense of rotation

9758

Speed sensor, slewing, differing frequency inputs

9759

Speed sensor, slewing, ground cable defective

9761

Pressure sensor, slewing, cable parting

9762

Pressure sensor, slewing, short circuit after supply voltage

9764

Pressure sensor, slewing pump connection A, cable parting

9765

Pressure sensor, slewing pump connection A, short circuit after supply voltage

9767

Pressure sensor, slewing pump connection B, cable parting

9768

Pressure sensor, slewing pump connection B, short circuit after supply voltage

9781

Control piston 1, cable parting, solenoid, lower hood

9782

Control piston 1, accidental ground, solenoid, lower hood

9783

Control piston 1, short circuit after supply voltage, solenoid, lower hood

WX210 - WX240

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

9784

Control piston 1, flow measurement deviation, solenoid, lower hood

9785

Control piston 1, defective cut-off, solenoid, lower hood

9786

Control piston 1, cable parting, solenoid, upper hood

9787

Control piston 1, accidental ground, solenoid, upper hood

9788

Control piston 1, short circuit after supply voltage, solenoid, upper hood

9789

Control piston 1, flow measurement deviation, solenoid, upper hood

9790

Control piston 1, defective cut-off, solenoid, upper hood

9791

Control piston 1, control fault

9792

Control piston 1, pilot valve defective

9796

Control piston 2, cable parting, solenoid, lower hood

9797

Control piston 2, accidental ground, solenoid, lower hood

9798

Control piston 2, short circuit after supply voltage, solenoid, lower hood

9799

Control piston 2, flow measurement deviation, solenoid, lower hood

9800

Control piston 2, defective cut-off, solenoid, lower hood

9801

Control piston 2, cable parting, solenoid, upper hood

9802

Control piston 2, accidental ground, solenoid, upper hood

9803

Control piston 2, short circuit after supply voltage, solenoid, upper hood

9804

Control piston 2, flow measurement deviation, solenoid, upper hood

9805

Control piston 2, defective cut-off, solenoid, upper hood

9806

Control piston 2, control fault

9807

Control piston 2, pilot valve defective

9811

Control piston 3, cable parting, solenoid, lower hood

9812

Control piston 3, accidental ground, solenoid, lower hood

9813

Control piston 3, short circuit after supply voltage, solenoid, lower hood

9814

Control piston 3, flow measurement deviation, solenoid, lower hood

9815

Control piston 3, defective cut-off, solenoid, lower hood

9816

Control piston 3, cable parting, solenoid, upper hood

9817

Control piston 3, accidental ground, solenoid, upper hood

9818

Control piston 3, short circuit after supply voltage, solenoid, upper hood

9819

Control piston 3, flow measurement deviation, solenoid, upper hood

9820

Control piston 3, defective cut-off, solenoid, upper hood

9821

Control piston 3, control fault

9822

Control piston 3, pilot valve defective

9826

Control piston 4, cable parting, solenoid, lower hood

9827

Control piston 4, accidental ground, solenoid, lower hood

9828

Control piston 4, short circuit after supply voltage, solenoid, lower hood

9829

Control piston 4, flow measurement deviation, solenoid, lower hood

9830

Control piston 4, defective cut-off, solenoid, lower hood

9831

Control piston 4, cable parting, solenoid, upper hood

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6 - 17

6 - 18

TROUBLESHOOTING AND REPAIR

9832

Control piston 4, accidental ground, solenoid, upper hood

9833

Control piston 4, short circuit after supply voltage, solenoid, upper hood

9834

Control piston 4, low measurement deviation, solenoid, upper hood

9835

Control piston 4, defective cut-off, solenoid, upper hood

9836

Control piston 4, control fault

9837

Control piston 4, pilot valve defective

9841

Control piston 5, cable parting, solenoid, lower hood

9842

Control piston 5, accidental ground, solenoid, lower hood

9843

Control piston 5, short circuit after supply voltage, solenoid, lower hood

9844

Control piston 5, flow measurement deviation, solenoid, lower hood

9845

Control piston 5, defective cut-off, solenoid, lower hood

9846

Control piston 5, cable parting, solenoid, upper hood

9847

Control piston 5, accidental ground, solenoid, upper hood

9848

Control piston 5, short circuit after supply voltage, solenoid, upper hood

9849

Control piston 5, flow measurement deviation, solenoid, upper hood

9850

Control piston 5, defective cut-off, solenoid, upper hood

9851

Control piston 5, control fault

9852

Control piston 5, pilot valve defective

9856

Control piston 6, cable parting, solenoid, lower hood

9857

Control piston 6, accidental ground, solenoid, lower hood

9858

Control piston 6, short circuit after supply voltage, solenoid, lower hood

9859

Control piston 6, flow measurement deviation, solenoid, lower hood

9860

Control piston 6, defective cut-off, solenoid, lower hood

9861

Control piston 6, cable parting, solenoid, upper hood

9862

Control piston 6, accidental ground, solenoid, upper hood

9863

Control piston 6, short circuit after supply voltage, solenoid, upper hood

9864

Control piston 6, flow measurement deviation, solenoid, upper hood

9865

Control piston 6, defective cut-off, solenoid, upper hood

9866

Control piston 6, control fault

9867

Control piston 6, pilot valve defective

9871

Control piston 7, cable parting, solenoid, lower hood

9872

Control piston 7, accidental ground, solenoid, lower hood

9873

Control piston 7, short circuit after supply voltage, solenoid, lower hood

9874

Control piston 7, flow measurement deviation, solenoid, lower hood

9875

Control piston 7, defective cut-off, solenoid, lower hood

9876

Control piston 7, cable parting, solenoid, upper hood

9877

Control piston 7, accidental ground, solenoid, upper hood

9878

Control piston 7, short circuit after supply voltage, solenoid, upper hood

9879

Control piston 7, flow measurement deviation, solenoid, upper hood

WX210 - WX240

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

9880

Control piston 7, defective cut-off, solenoid, upper hood

9881

Control piston 7, control fault

9882

Control piston 7, pilot valve defective

9886

Control piston 8 cable parting, solenoid, lower hood

9887

Control piston 8, accidental ground, solenoid, lower hood

9888

Control piston 8, short circuit after supply voltage, solenoid, lower hood

9889

Control piston 8, flow measurement deviation, solenoid, lower hood

9890

Control piston 8, defective cut-off, solenoid, lower hood

9891

Control piston 8, cable parting, solenoid, upper hood

9892

Control piston 8, accidental ground, solenoid, upper hood

9893

Control piston 8, short circuit after supply voltage, solenoid, upper hood

9894

Control piston 8, flow measurement deviation, solenoid, upper hood

9895

Control piston 8, defective cut-off, solenoid, upper hood

9896

Control piston 8, control fault

9897

Control piston 8, pilot valve defective

9901

Pressure relief valve, attachment, cable parting

9902

Pressure relief valve, attachment, accidental ground

9903

Pressure relief valve, attachment, short circuit after supply voltage

9904

Pressure relief valve, attachment, control fault

9905

Pressure relief valve, attachment, defective

9911

Left solenoid, auxiliary rotation circuit valve, cable parting

9912

Left solenoid, auxiliary rotation circuit valve, accidental ground

9913

Left solenoid, auxiliary rotation circuit valve, short circuit after supply voltage

9916

Right solenoid, auxiliary rotation circuit valve, cable parting

9917

Right solenoid, auxiliary rotation circuit valve, accidental ground

9918

Right solenoid, auxiliary rotation circuit valve, short circuit after supply voltage

9921

Valve, parallel driving, cable parting

9922

Valve, parallel driving, accidental ground

9923

Valve, parallel driving, short circuit after supply voltage

9926

Valve, volumetric flow summation cable parting

9927

Valve, volumetric flow summation accidental ground

9928

Valve, volumetric flow summation, short circuit after supply voltage

9931

General sensor, cable parting

9932

General sensor, short circuit after supply voltage

6 - 19

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6 - 20

TROUBLESHOOTING AND REPAIR

WX210 - WX240

Fault codes PCS unit


Code

Fault type

8000

ERR_BROKEN_WIRE_ENGINE

8001

ERR_BROKEN_WIRE_COOLER

8002

ERR_BROKEN_WIRE_OIL

8003

ERR_SHORT_WIRE_ENGINE

8004

ERR_SHORT_WIRE_COOLER

8005

ERR_SHORT_WIRE_OIL

8006

ERR_TEMP_ENGINE_WARN

8007

ERR_TEMP_ENGINE_OVER

8008

ERR_TEMP_OIL_WARN

8009

ERR_TEMP_OIL_OVER

8010

ERR_TEMP_AIR_OVER

8011

ERR_WIRE_PWM0

8012

ERR_WIRE_PWM1

8013

ERR_WIRE_PWM2

8014

ERR_WIRE_PWM3

8015

ERR_STATE_MACHINE

8016

ERR_RAM

8017

ERR_NVRAM

8018

ERR_ROM

8019

ERR_NVRAM_RESET

40000469-en

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

TROUBLESHOOTING AND REPAIR

6 - 21

Fault codes, Central Unit


Code

from Version

Fault type

40000468-en

Conditions

-----------------------------------------------------------------7000

0.30

ERR_ENGINE_OIL_PRESSURE

engine on

7001

0.30

ERR_STEERING_PRESSURE

engine on

7002

0.30

ERR_LOW_BRAKE_PRESSURE

7003

0.30

ERR_CAN_BUS_OFF_PCS

7004

0.30

ERR_CAN_BUS_OFF_ESX

7005

0.30

ERR_CAN_BUS_OFF_C4

7006

0.30

ERR_CAN_BUS_OFF_C51

7007

0.30

ERR_CAN_BUS_OFF_C52

7008

0.30

ERR_CAN_BUS_OFF_C53

7009b 0.32

ERR_ENGINE_OIL_PRESSURE_SENSOR

7009a 0.30

ERR_LOW_COOLANT_LEVEL

7010b 0.34a

ERR_ALTERNATOR_DPLUS_WIRE

7010a 0.30

ERR_ENGINE_OIL_LEVEL

7011

0.30

ERR_CALIBRATION

7012

0.30

ERR_HYDOIL_FILTER

engin on

7013

0.30

ERR_AIR_FILTER

engin on

7014

0.30

ERR_GREASE_LEVEL_INDICATOR

7015

0.30

ERR_FREQUENCY_SENSOR

7016

0.30

ERR_VDO_POTI_MAX

7017

0.30

ERR_VDO_POTI_MIN

7018b 0.31

ERR_POWER_ON_1

7018a 0.30

ERR_SUM_WHITE

7019

0.31

ERR_BYPASS_HAMMER

7020

0.31

ERR_BOOM_LIGHT

7021b 0.34a

ERR_ALTERNATOR_DPLUS

7021a 0.31

ERR_START_RELAIS

7022

0.31

ERR_BRAKE_LIGHT

7023

0.31

ERR_TRAVEL_LIGHTS

7024

0.31

ERR_POWER_SUPPLY

engine off

engine off

engin on

reserved

engin on

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

6 - 22

Code

TROUBLESHOOTING AND REPAIR

from Version

Fault type

WX210 - WX240

Conditions

-----------------------------------------------------------------7025

0.31

ERR_GEAR_OR_SEC_STEERING

7026

0.31

ERR_ECU_POWER_OR_PRESSURE_INCREASE

7027

0.31

ERR_HAZARD_LAMP_OR_STICK_STABS_RELAIS

7028

0.31

ERR_PARK_LIGHT_RIGHT

7029

0.31

ERR_LEFT_TURN_LIGHT

7030

0.31

ERR_PARK_LIGHT_LEFT

7031

0.31

ERR_RIGHT_TURN_LIGHT

7032

0.31

ERR_HORN

7033

0.31

ERR_AFTER_SRC_DRV_MOTOR

7034

0.31

ERR_ENGINE_CONTROLLER

7035

0.31

ERR_SNAIL_OR_OSCI_AXLE

7036

0.31

ERR_POWER_ON_2

7037

0.31

ERR_SUM_WHITE

reserved

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

Service manual
Section 7 Repair Instructions
WX210 - WX240

9-91270

7-2

REPAIR INSTRUCTIONS

WX210 - WX240

REPRODUCTION OF THESE OPERATING INSTRUCTIONS IN WHOLE OR


IN PART IS STRICTLY PROHIBITED EXCEPT WITH THE WRITTEN CONSENT
OF THE PUBLISHER

The data contained in this handbook were valid at the time of publication. As we constantly
endeavour to improve our products and to provide additional options, modifications or
changes made in this context may have an impact on the procedures described in this
handbook. Please contact your local dealer if you find any discrepancies.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7-3

7-4

REPAIR INSTRUCTIONS

WX210 - WX240

Table of contents

REPAIR INSTRUCTIONS............................................................................. 10
Foreword........................................................................................................................................ 10
Introduction ................................................................................................................................... 10
Safety instructions........................................................................................................................ 11
Risks resulting from failure to observe the safety instructions..................................................................... 11

Welding operations, safety instructions..................................................................................... 14


General welding instructions........................................................................................................................ 15
Protecting electronic modules during welding operations............................................................................ 16
Effect of electromagnetic fields and electrostatic discharges ...................................................................... 18

Handling of oils and greases ....................................................................................................... 19


Securing the machine................................................................................................................... 20
Depressurizing the hydraulic system / brake system ............................................................... 21
Working hydraulics....................................................................................................................................... 21
Pilot control .................................................................................................................................................. 21
Service brake ............................................................................................................................................... 21
Depressurizing the hydraulic system ........................................................................................................... 22

Bearings and bushings ................................................................................................................ 23


Removal of bearings and bushings.............................................................................................................. 23
Fitting of bearings and bushings .................................................................................................................. 24

SUPERSTRUCTURE COMPONENTS......................................................... 26
Replacing the buffers under the cab baseplate ......................................................................... 27
Preparations................................................................................................................................................. 27
Front buffers................................................................................................................................................. 27
Rear buffers ................................................................................................................................................. 27

Removing and refitting the cab ................................................................................................... 28


Preparations................................................................................................................................................. 28
Unplugging the electrical connectors ........................................................................................................... 28
Dismantling the cab...................................................................................................................................... 29
Refitting the cab ........................................................................................................................................... 29

Driver's seat................................................................................................................................... 30
Preparations................................................................................................................................................. 30
Removing the driver's seat........................................................................................................................... 30
Installing the driver's seat............................................................................................................................. 30

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7-5

Steering column, steering valve.................................................................................................. 31


Preparations................................................................................................................................................. 31
Removing the steering column with the steering valve................................................................................ 32
Refitting the steering column and the steering valve ................................................................................... 32
Removing the steering column .................................................................................................................... 32
Refitting the steering column ....................................................................................................................... 32

Control levers................................................................................................................................ 33
Preparations................................................................................................................................................. 33
Replacing the control lever .......................................................................................................................... 33

Display ........................................................................................................................................... 34
Preparations................................................................................................................................................. 34
Removing the display unit............................................................................................................................ 34
Refitting the display unit............................................................................................................................... 34

ESX Box ......................................................................................................................................... 35


Preparations................................................................................................................................................. 35
Removing the ESX Box ............................................................................................................................... 35
Refitting the ESX Box .................................................................................................................................. 35

Load-limit regulator ...................................................................................................................... 36


Preparations................................................................................................................................................. 36
Removing the load-limit regulator ................................................................................................................ 36
Refitting the load-limit regulator ................................................................................................................... 36

Removing and installing the battery ........................................................................................... 37


Combined radiator ........................................................................................................................ 38
Preparations................................................................................................................................................. 38
Removing the combined radiator ................................................................................................................. 38
Refitting the combined radiator .................................................................................................................... 38

Battery box .................................................................................................................................... 39


Preparations................................................................................................................................................. 39
Battery box, removing the hood ................................................................................................................... 39
Battery box, refitting the hood ...................................................................................................................... 39

Fan door......................................................................................................................................... 40
Preparations................................................................................................................................................. 40
Removing the fan door................................................................................................................................. 40
Refitting the fan door.................................................................................................................................... 40

Battery box panelling ................................................................................................................... 41


Removing the metal panel ........................................................................................................................... 41
Refitting the metal panel .............................................................................................................................. 41

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7-6

REPAIR INSTRUCTIONS

WX210 - WX240

LINK BETWEEN SUPERSTRUCTURE AND


UNDERCARRIAGE COMPONENTS ........................................................... 42
Rotor .............................................................................................................................................. 43
Preparations................................................................................................................................................. 43
Removing the rotor....................................................................................................................................... 43
Refitting the rotor.......................................................................................................................................... 43

Slewing gearbox ........................................................................................................................... 44


Preparations................................................................................................................................................. 44
Removing the slewing gearbox.................................................................................................................... 44
Slewing gearbox, fitting ................................................................................................................................ 44
Dismantling and assembling the slewing gearbox....................................................................................... 44

Ball-bearing slewing ring ............................................................................................................. 45


Preparations................................................................................................................................................. 45
Removing the ball-bearing slewing ring ....................................................................................................... 46
Fitting the ball-bearing slewing ring ............................................................................................................. 47

UNDERCARRIAGE COMPONENTS ........................................................... 49


Axles and gearboxes .................................................................................................................... 50
Instructions for the repair of gearboxes and axles....................................................................................... 50
Testing procedures ...................................................................................................................................... 50

Brake disks, checking the lining thickness................................................................................ 51


Preparations................................................................................................................................................. 51
Checking ...................................................................................................................................................... 51

Bleeding the multiple-disk brake................................................................................................. 52


Preparations................................................................................................................................................. 52
Bleeding ....................................................................................................................................................... 52

Cardan shaft .................................................................................................................................. 54


Removing the cardan shaft .......................................................................................................................... 55
Refitting the cardan shaft ............................................................................................................................. 55

Rigid axle ASP100......................................................................................................................... 56


Removing the rigid axle ............................................................................................................................... 57
ASP100 tightening torques .......................................................................................................................... 58
Refitting the rigid axle................................................................................................................................... 59

Rigid axle, hydraulic motor and flanges..................................................................................... 60


Removal and fitting of hydraulic motor and flanges..................................................................................... 60

Rigid axle, gearbox housing ........................................................................................................ 62


Removing and fitting the gearbox housing .................................................................................................. 62

Ridid axle, differential unit ........................................................................................................... 64


Removing and fitting the differential unit...................................................................................................... 64

Rigid axle, pinion unit................................................................................................................... 66


Removing and fitting the pinion group ......................................................................................................... 66

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7-7

Steered axle ALPP100 .................................................................................................................. 68


Removing the steered axle .......................................................................................................................... 69
Tightening torques ALPP100 ....................................................................................................................... 72
Refitting the steered axle ............................................................................................................................. 73

Steered axle, steering cylinder .................................................................................................... 74


Removal and fitting of the steering cylinder................................................................................................. 74

Steered axle, reducer gear ........................................................................................................... 76


Removal and fitting of the reducer gear....................................................................................................... 76

Steered axle, articulated joint housing ....................................................................................... 78


Removal and fitting of the articulated joint housing ..................................................................................... 78

Steered axle, differential unit....................................................................................................... 80


Removal and fitting of the differential unit.................................................................................................... 80

Steered axle, pinion group........................................................................................................... 82


Removal and fitting of the pinion group ....................................................................................................... 82

Floating-axle cylinder ................................................................................................................... 83


Removing the cylinders................................................................................................................................ 84
Replacing the rod seal ................................................................................................................................. 84
Repairing the check valve............................................................................................................................ 85
Recommissioning and bleeding ................................................................................................................... 85

Speed sensor ................................................................................................................................ 86


Wheels ........................................................................................................................................... 87
Safety instructions........................................................................................................................................ 87
Tyre pressure, checking and topping up...................................................................................................... 88
Tyre inflation pressure table...................................................................................................................... 88
Fastening of wheels ..................................................................................................................................... 90
Wheels ......................................................................................................................................................... 91
Changing a wheel ........................................................................................................................................ 92
Fitting new wheels........................................................................................................................................ 92
Wheels, tread position ................................................................................................................................. 93

Steps, left side............................................................................................................................... 94


Preparation................................................................................................................................................... 94
Removing the steps on the left side............................................................................................................. 94
Installing the steps on the left side............................................................................................................... 94

Steps, right side, tool-box............................................................................................................ 95


Preparation................................................................................................................................................... 95
Removing the steps on the right side........................................................................................................... 95
Fitting the steps on the right side ................................................................................................................. 95
Dismantling the tool-box .............................................................................................................................. 96

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7-8

REPAIR INSTRUCTIONS

WX210 - WX240

Stabilizers ...................................................................................................................................... 97
Safety instructions........................................................................................................................................ 97
Outriggers .................................................................................................................................................... 97
Levelling blade ............................................................................................................................................. 97

Outriggers...................................................................................................................................... 98
Preparations................................................................................................................................................. 99
Removing the outriggers.............................................................................................................................. 99
Refitting the outriggers............................................................................................................................... 101

Levelling blade ............................................................................................................................ 102


Preparations............................................................................................................................................... 102
Removing the levelling blade ..................................................................................................................... 102
Refitting the levelling blade ........................................................................................................................ 102

Outrigger cylinders..................................................................................................................... 103


Outrigger cylinder components .................................................................................................................. 103
Preparations............................................................................................................................................... 103
Removing the outrigger cylinders .............................................................................................................. 103
Refitting the outrigger cylinders ................................................................................................................. 103
Outrigger cylinders, tightening torques ...................................................................................................... 103

Levelling blade cylinders ........................................................................................................... 104


Levelling blade cylinder components ......................................................................................................... 104
Preparations............................................................................................................................................... 104
Removing the levelling blade cylinders...................................................................................................... 104
Refitting the levelling blade cylinders......................................................................................................... 104
Levelling blade cylinders, tightening torques ............................................................................................. 104

EQUIPMENT, COMPONENTS ................................................................... 105


Boom cylinders for monoblock booms .................................................................................... 106
Preparations............................................................................................................................................... 106

Boom cylinders for boom shift equipment............................................................................... 107


Preparations............................................................................................................................................... 107

Boom cylinder ............................................................................................................................. 108


Removing the boom cylinder ..................................................................................................................... 108
Refitting the boom cylinder ........................................................................................................................ 110
Boom cylinder, components....................................................................................................................... 112
Dismantling the boom cylinder................................................................................................................... 114
Tightening torques ..................................................................................................................................... 115
Assembling the boom cylinder ................................................................................................................... 115

Stick cylinder............................................................................................................................... 117


Preparations............................................................................................................................................... 117
Removing the stick cylinder ....................................................................................................................... 118
Refitting the stick cylinder .......................................................................................................................... 119
Stick cylinder, components ........................................................................................................................ 120
Dismantling the stick cylinder..................................................................................................................... 122
Tightening torques ..................................................................................................................................... 123
Assembling the stick cylinder..................................................................................................................... 123

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7-9

Bucket cylinder ........................................................................................................................... 126


Preparations............................................................................................................................................... 126
Removing the bucket cylinder.................................................................................................................... 127
Refitting the bucket cylinder....................................................................................................................... 129
Bucket cylinder, components ..................................................................................................................... 130
Dismantling the bucket cylinder ................................................................................................................. 132
Tightening torques ..................................................................................................................................... 133
Assembling the bucket cylinder ................................................................................................................. 133

Adjusting cylinder....................................................................................................................... 135


Preparations............................................................................................................................................... 135
Removing the adjusting cylinder ................................................................................................................ 136
Refitting the adjusting cylinder ................................................................................................................... 137
Boom adjusting cylinder, components ....................................................................................................... 138
Dismantling the boom adjusting cylinder ................................................................................................... 138
Tightening torques ..................................................................................................................................... 138
Assembling the boom adjusting cylinder ................................................................................................... 138

WEAR PARTS ............................................................................................ 139


Slip-on tooth................................................................................................................................ 140
Safety instructions...................................................................................................................................... 140
Replacing the slip-on teeth ........................................................................................................................ 140

Trenching grab, wear limits ....................................................................................................... 141


Reworking the stops................................................................................................................................... 141

Lamp bulbs.................................................................................................................................. 142


Replacing the lamp bulbs, instructions ...................................................................................................... 142
Bulb table ................................................................................................................................................... 142
Replacing the headlamp bulb .................................................................................................................... 142
Replacing the lamp bulb in the front direction indicator lamp ................................................................... 143
Replacing the lamp bulb of the cab interior lamp....................................................................................... 143
Replacing the lamp bulb of the tail-light..................................................................................................... 144
Replacing the lamp bulb of the cab floodlamp........................................................................................... 144
Replacing the lamp bulb of the boom floodlamp........................................................................................ 145

ENGINE ...................................................................................................... 146

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 10

REPAIR INSTRUCTIONS

WX210 - WX240

REPAIR INSTRUCTIONS

40000060-en

Foreword

Introduction

The present handbook contains instructions for the


repair of components together with information on
removal and fitting of the same, and where necessary reference to other special technical handbooks.

The Technical Handbook contains important information for machine service personnel.

Topics:

Machine characteristics stated elsewhere in the


documention are not necessarily repeated in this
handbook.
The machine documentation consists of:

- Superstructure
- Driver's cab

- Operating instructions
- Spare-parts list

- Pumps

- Dimension tables or dimensional data sheets


with the technical characteristics of the machine.

- Valves
- Link betweeen superstructure and undercarriage
- Rotor
- Slewing ring
- Slewing gearbox
- Undercarriage
- Axles with gearbox and motors
- Wheels

The present handbook does not contain the characteristics of auxiliary units required for the operation of accessories or optional equipment.
The refilling quantities indicated for consumables
are approximate values and intended only as
guideline for demand planning.
Each unit is equipped with suitable monitoring devices such as dipstick or check plugs permitting to
determine the proper filling levels.

- Steps
- Stabilizers
- Cardan shaft
- Equipment
- Fitting and removal
- Cylinders
- Wear parts
- Engine

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 11

Safety instructions

40000268-de

Risks resulting from failure to observe the


safety instructions
This hydraulic excavator has been
built in accordance with state-ofthe-art standards and recognized
safety regulations.
Nevertheless, its use may constitute a risk if it continues to be operated despite damage being suspected or having occurred, or if it is
inexpertly repaired.
There is then a risk of
-

life-threatening injury

irreparable damage to the machine and other assets.

The hydraulic excavator must be


stopped immediately if suspected
damage or damage that has occurred affects the safety of the operator, other persons at the excavator deployment site, or other assets. All components are carefully
coordinated. Trouble-free operation
and a long service life are assured
only if original spare parts are
used.

Personnel
Unauthorised people must not set
the machine going. Therefore the
machine must be secured.
The Accident Prevention
must be complied with.

Rules

Only skilled and authorised personnel, which must have the corresponding expert knowledge, may
operate the hydraulic excavator or
carry out maintenance and repair
works on it.
If there is no expert knowledge,
experienced personnel must provide for an accurate training.
The Operating Instructions, in particular the section Fundamental
Safety Requirements , must have
been read and understood.
Only this people may put the machine into operation during assembly works to carry out adjustments
on the working equipment.
Incorrect operating on the machine
or working equipment can be dangerous to life.
The turn-on and turn-off procedures, specified in the Operating
Instructions, must be complied with
for all operations.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 12

REPAIR INSTRUCTIONS

WX210 - WX240

Personnel

Working Equipment Securing

Personal protective outfit and working clothes:

Before carrying out assembly operations, secure device and equipment against unintentional and
unauthorized setting into motion,
e.g. the chassis by means of wheel
chocks and the working equipment
by putting it down on the ground.

wear safety helmet, work protective


shoes and gloves.
Wear close-fitting working clothes,
when you are attending on the machine. Loose, wide garments can
get caught on parts of the machine
and cause injuries.
If some assistants are required during the operations, e.g. instructors,
previously the responsibility of each
single person must be clearly defined.
When operating the spheres of
competence must be strictly adhered to, so that no unclear responsibilities would arise in the field of
safety.

Tools and auxiliary material


Tools, tackles and stopping devices,
supporting trestles and other auxiliary material must be in operational
and working safety condition.
When driving in and out bolts of
equipment, metallic splinters can
cause injuries. Therefore while driving in and out, use a drift pin of
brass or copper and wear eyeprotection glasses.
For getting on and off, use only the
designed ladders, steps, platforms
and handgrips.

Put the equipment on the ground


so, that no motion can be caused
while loosing mechanical or hydraulic connecting parts.
Secure equipment or components,
which have to be fitted or dismounted or modified in their
mounting position by means of
tackles or appropriate mounting
and supporting devices against
unintentional motion, slipping or
dropping.
Before opening, systems and assemblies (e.g. pipings, accumulators) are to be made unpressurised
in a suitable way.
Protective devices of movable machine parts may be opened or removed only when the driving system is put out of operation and secured against unintentional setting
into motion.
Before reinstating into operation,
all protective devices must be reinstalled!

Maintain ladders, steps and platform


in running safety condition and
handles in gripping safety condition.
Remove immediately any soiling
caused by oil, grease, ground, mud,
snow, ice and other substances.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 13

Hydraulic and Lubricating


System

Conversions or Modifications
on the Machine

When handling oils, greases and


other chemical substances, the
safety requirements that apply to
the product are to be complied with.

Arbitrary conversions or modifications on the hydraulic excavator are


not permitted due to safety reasons.

Not necessary but uncovered holes,


pipe and hose unions are to be
closed in a compression-proof
manner.
Fill the collected hydraulic oil into
the hydraulic system only through
the return pipe filter. Dispose not reused oils in a way correct from an
environmental point of view.
Observe the sequence of the working operations when mounting or
replacing components or outfits.
It was defined and tried by experienced specialists.
In case of operations, in particular
on the electric system, in which
tools, spare parts, etc. may come in
touch with electric lines, the battery
main switch must be turned in the
position OFF.
Damaged, mechanically pre-loaded
units must be completely replaced.
Do not open! Or in exceptional
cases only when the system and the
working cycle is known with precision.

Also the nominal pressure of the


pressure limiting valves must not be
changed.
Do not remove lead seals from the
pressure limiting valves and hydraulic accumulators.

Reinstatement into Service


Before reinstating into service:
-

lubricate all lubricating points,

test all oil levels, if necessary correct them,

carry out a functional test of the


repaired components.

Test all functions of the excavator


including braking in test run and
release the hydraulic excavator for
the reinstatement into service only
if it runs in all its functions without
objections.

The technical handbook contains no


information in this respect.
At the operating temperature of the
machine, when the operating fluids
have the same temperature at least,
take suitable measures to prevent
burns and scalds.
Caution when handling acids.
Also a splash of acid can cause eye
and skin injuries.
Do not smoke when handling flammable liquids.
Caution with fire and open light. Not
only fuel but also other operating
fluids have often low flash points
and can lightly ignite.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 14

REPAIR INSTRUCTIONS

WX210 - WX240

Welding operations, safety instructions

40000352-en

Never perform welding operations


unless you are qualified to do so.

Prior to any welding operations on the machine:

Observe the accident prevention regulations.

Disconnect battery by disconnecting first negative pole terminal,


then positive pole terminal

Disconnect positive pole terminal


at three-phase alternator (generator)

Detach corresponding terminals


and plugs from the electronic control units (read and observe: Protecting electronic control units during welding operations).

Protect disconnected terminals


and plugs from short-circuiting
and soiling by covering them with
foil or adhesive tape.

Any work on receptacles that contain or have contained substances


-

that are combustible or encourage


combustion,

that are susceptible to explosion or

that may develop health-hazardous


gases, vapours, mist or dust during welding operations

must be carried out only under expert supervision and only by experienced persons authorized to do
such work.
Systems and units (e.g. piping, radiator, hydraulic tank, compressed-air
reservoir) must be depressurized
prior to being opened.
Detailed information on the correct
execution of welding operations is
given in the Technical Manual
"Welding for maintenance and repair".
Should you have any problems or
queries, apply to our service department.
If parts of the machine have to be
dismantled, read and observe the
following sections:
"Installing attachments, safety instructions",
"Inspection and servicing, safety instructions",
"Repair, safety instructions".

Attach the welding-current pincers


in the immediate vicinity of the
welding zone.
Never connect the grounding terminal of the welding equipment with
electronic components or with the
attachment points of these components.
It is not advisable to carry out welding operations on the engine or on
components mounted on the engine, as this may damage the components.
The welding current must not flow
via the ball-bearing slewing ring or
via pin couplings, articulated joints
or hydraulic cylinders.
On completion of the welding operation, restore all electrical connections.
When reconnecting the battery, connect first the positive pole terminal,
then the negative pole terminal.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

General welding instructions

7 - 15

- Prior to disconnecting the batteries, ventilate the


battery case thoroughly (detonating gas), e.g. by
blowing out with compressed air.

Observe accident prevention regulations, in particular:

- Attach grounding pliers of welding unit with good


conductivity directly to the area to be welded.

Avoid inhaling gases/vapours constituting a health hazard, e.g. engine exhaust vapours, hazardous
substances released in the welding
process, vapours from cleaning
agents and solvents. Draw them off
with appropriate suction equipment.

- If two components are to be welded together,


they must be connected to each other with good
conductivity (e.g. connect the two components
with the grounding pliers).

Secure machine against inadvertent movement.

Secure units when dismantling.

Observe handling instructions for


machines and attachments (see also: "Welding, safety instructions").

Thorough preparation of the weld area is essential


to the production of a high-grade weld. Sensitive
components must be protected or dismantled. The
weldment connecting points to the machine and
ground terminal at the welding unit must be bright;
therefore remove any paint, rust, oil, grease, dirt
etc. The welding work must be done with direct
current only; the polarity of the electrodes must be
checked. Welders must be sufficiently qualified to
carry out welding work on vehicles. Therefore
specialized training is a precondition for such
work. In Germany this is subject to a verification of
suitability in accordance with DIN 18800, part 7.
Welding must NOT be done when the ambient
temperature falls to below +5C.

- The frames of our machines are made of highstrength fine-grain steels. The frame material is
suitable for all tested and recognized arc welding procedures, including the inert-gas-shielded
arc process. Any type of heat treatment is inadmissible.
Only at the following steel components of attachments and modules may welding be done, with
cross sections not being changed in any way in
shape or area:
- trenching attachments (e.g. buckets; clamshells)
- toggle lever and linking elements
- sticks
- top boom section / bottom boom section / monoblock boom
- superstructure frame
- undercarriage frame
- stabilizers (claws) and dozer blade
Any other welding work is inadmissible.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 16

REPAIR INSTRUCTIONS

WX210 - WX240

Protecting electronic modules during


welding operations
To prevent damage to electronic
modules (e.g. CU, PCS, ESX, display, keyboard modules) during
welding operations, the procedure
set out below must be observed.

3rd point (ESX)


The ESX is located to the right below the cab,
beside the slewing ring. The grounding cable (3,
Fig. 6) is located to the right beside the ESX.
- Unscrew base plate.

- Disconnect the negative and positive battery


cables (see: Battery removal and installation)
and join loose cable ends (- with +).
Unplug the connectors of the electronic modules and the ground connection.
The connectors to the electronic components and
the grounding system must then be unplugged at
3 points.
1st point (PCS)
- Remove rear wall of drivers cab (Fig. 1).
- In some cases, a cover to the rear of the drivers
cab must also be removed.
- Push arresting lever (1, Fig. 2) away from plug
and withdraw plug (2) of PCS unit upwards. At
the front of the plug is an extension (nose) that
has to be disengaged in this process.
2nd point (CU)
- The CU is located below the plate on which the
PCS is mounted. The plate is fixed to the rear
wall of the drivers cab with 3 screws (Fig. 3).

- Disconnect grounding cable between frame and


cab/platform plate (Fig. 5), insulating the
grounding cable in such a way that no ground
connection can be inadvertently restored.
- Withdraw arresting lever (1, Fig. 6) at plug forward, and withdraw plug (2) parallel from the
control unit.
Once all working steps have been executed, welding operations can be carried out on the machine
(read and observe: Welding operations safety
instructions and Welding instructions).
On completion of the welding operation, reconnect
all plug and grounding connections by performing
the steps listed above in the reverse sequence.
Failure to observe this procedure
will rule out any liability and warranty coverage for resulting damage.

- Withdraw plugs (1 - 5, Fig. 4) from CU, pressing


laterally on the plug arresting device. Mark the
connectors correspondingly in advance to avoid
mix-ups when plugging together.
- Disconnect three further plugs located on a
separate p.c. board to the right beside the CU
(not shown).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Fig. 1

Fig. 4

Fig. 2

Fig. 5

Fig. 3

Fig. 6

7 - 17

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 18

REPAIR INSTRUCTIONS

Effect of electromagnetic fields and electrostatic discharges


Strong electromagnetic fields resulting from highvoltage cables, lightning stroke current, transmitter
systems or other sources of interference can influence electronic modules in the machine and may
lead to malfunctions.
Mobile phones or radio equipment must not be
used inside the drivers cab unless they have a
separate external antenna.
The use of mobile phones and radio equipment
with no external antenna may result in excessive
electromagnetic fields (resonance effects) inside
the cab. In this case there is a risk of malfunctions
in the machine electronics.

WX210 - WX240

Electrostatic discharges may also cause irreparable damage to electronic components.


If inexplicable malfunctions occur in the machine,
stop the machine and secure it. If lightning strikes
close to the machine, wait in the drivers cab until
the thunderstorm is over.
For safety reasons, work must not
be continued in the event of inexplicable malfunctions in the machine.
In such cases, contact our Service
Department immediately.

Mobile phones or radio equipment


with no separate external antennas
may constitute a health hazard due
to excessive electromagnetic fields
if operated inside the drivers cab.
Attention must be paid to the operating instructions issued for the
mobile phones and radio equipment.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Handling of oils and greases


Handling of oils and greases
Skin contact with used oils can be a
health hazard.
Avoid contact with the skin. Wear
gloves and firm working footwear.
Wash soiled skin thoroughly with
warm soapy water and protect with a
barrier cream. Do not use fuels or
solvents for cleaning of the skin.
If you have swallowed oil, do not
induce vomiting, but consult a doctor immediately.

Visible oil losses


When oil losses are visible, have the
corresponding leaks repaired immediately.

7 - 19

40000294-en

Disposal without polluting the


environment
Dispose of oils, greases, detergents,
solvents and oil-containing components, e.g. filters, cleaning rags, replaced wear parts und unusable machine parts without polluting the environment and separately from each
other.
Do not discard these substances together with ordinary domestic wastes.
Fill the substances into the containers provided for this purpose.
Do let oils and oil-containing substances penetrate into the soil or
into water. They are a danger to the
environment.

Escaping oil is a danger to the environment.


Absorb escaping oil with oil-binding
agents. Collect oil-binding agents
and dipose of separately from other
wastes.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 20

REPAIR INSTRUCTIONS

WX210 - WX240

Securing the machine

Risk of injury
The machine must not be started by
unauthorized persons.
The machine must therefore be secured.

Secure the machine as described below:


- before performing any modification or fitting work
on the working equipment;
- before performing any servicing or repair work on
the machine.
- Park the machine on level and firm ground.
- Lock the superstructure.
- Stand the working equipment on the ground.
- Apply the parking brake.

40000270-en

Do not shut off the engine from full


load, but rather let it continue to run
at idling for about 3 minutes for cooling down.
Shut off the automatic speed reduction function before shutting off the
engine as there will otherwise be no
'WARMUP' phase during the next
start-up and the engine will run immediately at full speed.

Shut off the engine.


- Turn the electrical system key-switch to position I
(ignition ON).
- Depressurize the hydraulic system.
- Withdraw the key from the electrical system keyswitch.
- Shut off the pilot control.
- Turn off the battery main switch and withdraw the
lever.
- Before working on the electrical system or before
performing welding work on the machine, disconnect the batteries.
- Insulate the connecting terminals.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Depressurizing the hydraulic system / brake system

Hydraulic systems may be opened


only after they are depressurized.
Even after a machine has been
parked on a horizontal surface with
its working equipment resting on
the ground and with its drive drive
engine shut off, there may still be a
substantial amount of residual pressure in parts of the hydraulic system:
-

Primary pressure left over from the


last hydraulic movements before
shut-down.

Secondary pressure resulting from


the excavator's own weight or from
the weight of individual components of the working equipment.
Secondary pressure is present until
the pressure-generating components have reached a position of
rest, e.g. on a mechanical support,
and must therefore no longer be
sustained by the hydraulic system.

Precharging pressures in the hydraulic system induced by design


constraints.

Residual pressure will disappear only gradually. If


work on the hydraulic system is to be performed
immediately after shut-down, the system must be
depressurized, i.e. the pressure must be removed.
- Locate the system section to be opened.
- Depressurize the system section to be opened.
It may also be necessary to combine several of
the measures described above.
- Open the depressurized section carefully.

7 - 21

40000271-en

The system comprises the following sections:


- Working hydraulics
- Pilot control
- Service brake
Depressurizing:

Working hydraulics
- Move all control levers after shut-down inside
the precision control range.
These activities must be planned carefully since
the capacity of the pressure accumulator which
now feeds the pilot-control system is limited and
pressure is reduced by leakage oil losses.

Fig. 1

Pilot control
- Move the control levers several times fully into
all directions. After about 30 control movements
the pressure remaining thereafter being only 2
bars the pilot-control system can be opened.

Service brake
- Depressurize the hydraulic accumulator by depressing the pedal valve repeatedly.
Pressure can be removed faster from the accumulators if minimess hoses are connected to the
bleeding ports on the front and rear axles.
Hold the hose ends into a collecting recipient for
oil and depress the pedal valve repeatedly.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 22

REPAIR INSTRUCTIONS

WX210 - WX240

Depressurizing the hydraulic system


Before beginning the work, the hydraulic system
must be depressurized:
- Stand the working equipment on the ground.
- Shut off the engine.
- Turn the electrical system key-switch to position I
(ignition ON).
- Switch on the pilot control (lever 72).
- Move the control lever or the pedal of the cylinder on which work is to be performed into both
directions.
Special caution is required when
working on cylinders equipped with
pipe break systems. After actuation
of the control levers and pedals,
the cylinders may still contain residual pressure.

Fig. 2

In boom cylinders with pipe break


systems on the piston side, this
residual pressure can be removed
by lifting the undercarriage about
10 cm. In this case, the machine is
pressure-supported by the rod side
of the cylinder. The piston side to
be opened is without pressure.
In adjusting cylinders or in stick cylinders with a pipe break system on
the rod side, the residual pressure
can be removed by retracting the
respective cylinder almost completely, with the undercarriage being raised about 10 cm with the
extended working equipment. In
this case, the machine is pressuresupported by the piston side of the
respective cylinder. The rod side to
be opened is without pressure.

Fig. 3

- Turn the electrical system key-switch to position


0 (ignition OFF).
- Switch off the pilot control (lever 72).
Remove the precharging pressure in the hydraulic
oil reservoir by inserting the locking pin into the
side of the breather valve (Fig. 3). Unscrew the
valve (Fig. 2) carefully until the breather bore is
open (audible hiss).
The residual pressures in the working equipment
and in the hydraulic pilot control are now removed.
Retighten the valve by hand and withdraw the locking pin.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Bearings and bushings

7 - 23

40000269-en

Removal of bearings and bushings


Before removing a bearing, the surroundings of
the bearing must be properly cleaned and any
existing safety devices (lock-washers, screw locking agents, etc.) removed.
Check how the bearing to be removed was installed by reading the corresponding chapter and
choose the tools and the dismantling procedure
accordingly.
Outer rings of bearings installed with a tight fit in a
housing can, for instance, be driven out more
easily when the the housing is uniformly heated
beforehand.
The forces required for removing a bearing must
always be counteracted by the corresponding
opposite forces. These counteracting forces
should always be applied als closely as possible
to the bearing to be removed. It is necessary to
ensure that the forces and impact pressures applied for the removal of a bearing can under no
circumstances damage other components of the
assembly under repair. It may therefore be necessary to detach the component containing the bearing to be replaced beforehand from the main assembly.
Figure 1
The force "F" needed to remove a bearing (2)
from a housing (1) must always be applied by
means of an assembly mandrel (4) of suitable
dimensions to the outer ring of the bearing.

Fig. 1

Figure 2
Bearings (2) should be extracted from shafts (1)
using a special extraction tool, e.g. a double-leg or
a triple-leg extractor (3). In this case, too, the
force "F" needed for the extraction should be applied as closely as possible to the seat of the
bearing, i.e. the inner ring.
The counteracting force "F 1" acts in this case
through the extractor spindle (3) on the shaft (1).

The housing (1) must be supported as closely as


possible to the bearing with spacers or a spacing
sleeve (3).
The spacers must be designed in such a way that
they are able to transfer counteracting force "F 1"
to the housing (1).

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 24

REPAIR INSTRUCTIONS

Fitting of bearings and bushings


Unless expressly stated otherwise,
roller bearings are on principle installed in such a way that the side
with the inscription is visible after
fitting.

WX210 - WX240

Figure 4
When installing circular seals such as rotary shaft
seals (2) into a housing (1), a suitable assembly
mandrel or assembly sleeve (3) is to be used to
avoid damaging the element.

The information supplied on the previous page for


the removal of bearings applies analogously also
to the fitting of bearings.
Figure 3
When installing a bearing (2) into a housing (1), the
fitting force "F" required must be applied with a
suitable assembly mandrel (3) to the outer ring of
the bearing (2). To cope with counteracting forces
"F 1", the housing (1) should be supported as
closely as possible to the bearing.

Fig. 4

Figure 5
When a bearing (2) is fitted on a shaft (1), the assembly foce "F" must be applied by means of a
fitting sleeve (3) to the inner ring of the bearing.
The shaft end opposite the fitting direction of the
bearing must be properly supported to cope with
counteracting force "F 1".

Fig. 3

Fig. 5

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 25

7 - 26

REPAIR INSTRUCTIONS

WX210 - WX240

SUPERSTRUCTURE COMPONENTS
Superstructure
Replacing the buffers
Removing the driver's cab
Removing the seat
Removing the steering column
Removing the joysticks
Removing the display
Removing the ESX box
Removing the load-limit regulator
Gear pumps
Single

steering/brake

Double

steering/brake and grab rotation

Displacement pump
Valve stacking
Removing the battery
Removing the combined radiator
Removing the fuel tank
Removing the oil reservoir
Removing the counterweight at the rear
Removing the monoblock

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000221-en

WX210 - WX240

REPAIR INSTRUCTIONS

Replacing the buffers under the cab baseplate

7 - 27

40000296-en

Fig. 1

Legend
1
2
3
4
5
6
7

4
16
16
2
4
2
2

Buffer
Screw
Disk
Screw
Disk
Screw
Disk

Preparations
- Secure the machine as described under 'Securing the machine'.

Place a timber beam between the


baseplate and the frame to ensure
that the fitting space does not narrow: risk of crushing.

- Loosen and remove the screws (2) and the disks


(3) retaining the buffers.
- Lift the buffer out of its housing and replace.

Front buffers

- Fasten the buffer with the screws (2) and the


disks (3), remove the safety timber and lower the
cab cautiously.

- Remove the rubber mats over the screws to be


loosened.

- Fasten the baseplate with the cab using the


screws (4) and (5).

- Loosen and remove the front screws (4).


- Loosen the rear screws (6), but without removing
them.
- Raise the front part of the cab with the baseplate
slightly so that the screws of the buffers can be
removed.

Rear buffers
- To replace the rear buffers, observe the same
working steps as described for the front buffers.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 28

REPAIR INSTRUCTIONS

WX210 - WX240

Removing and refitting the cab

40000297-en

Fig. 1

Preparations
- Secure the machine as described under 'Securing the machine'. Shut off the engine and the ignition.

Unplugging the electrical connectors

Fig. 2

- Remove the step (4) behind the driver's cab


(Fig. 2) by loosening and removing the screws
(5).
- Remove the cover over the electronics compartment behind the cab.

Fig. 3

- Unplug the connectors X12A, X12B and XCAN.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 29

Dismantling the cab

Refitting the cab

- Remove the floor mats from the cab.

- Position the cab with the crane over the baseplate and fasten it with the screws (1).

- Loosen the six screws (Fig. 1, 1) fixing the cab


(3) to the baseplate.
- Screw the 4 eye-bolts (6) into the bores provided
in the cab roof.
- Attach the cab with suitable ropes or chains
through the eye-bolts to a crane.

- Place the floor mats into the cab.


- Re-establish the electrical connections.
- Close the electronics compartment and fasten
the cover with screws.
- Refit the step.

- Lift the cab cautiously off the baseplate.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 30

REPAIR INSTRUCTIONS

WX210 - WX240

Driver's seat

40000298-en

Fig. 1

Preparations
- Secure the machine as described under 'Securing the machine'.

- Loosen the four screws (3) fixing the driver's


seat.

Removing the driver's seat

- Unplug the connector for the automatic height


adjustment.
- Remove the driver's seat cautiously from the
cab.

Weight of the seat:


Seek the assistance of a second
person when lifting the seat out of
the cab.

Installing the driver's seat


Fig. 2

The driver's seat (1) is installed on a slide rail


which accomodates also the operating consoles of
the excavator.

- Lift the seat into the cab and position it over the
screw holes.
- Fasten the driver's seat with the four screws (3).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Steering column, steering valve

7 - 31

40000299-de

Preparations

- Shut off the engine and the ignition.

Secure the machine as described under 'Securing


the machine'.

- Detach the steering column panelling (1) and (2)


by removing the fastening screws (3).
- Unplug the connectors of the operating elements
on the panels and remove the panelling.
- Unplug the connectors of the steering column.

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 32

REPAIR INSTRUCTIONS

WX210 - WX240

Removing the steering column with the


steering valve

Removing the steering column

Fig. 2

Fig. 3

- Depressurize the hydraulic system, remove all


hoses from the steering valve and close the
openings of the hoses and of the valve.

- Mark the position of the steering column in the


steering valve.

Collect any escaping oil in a suitable


recipient and discard without polluting the environment.

- The steering valve is fastened to the steering


column with the screws (5). Loosen these screws
and remove them together with the disks (6) and
the spacers (7) and (8).
- Loosen the screws (4) retaining the steering column in the cab as described before and remove
the steering column.

- Loosen and remove the four screws (4) and


withdraw the complete unit.

Refitting the steering column and the


steering valve
- Slide the preassembled steering column with the
steering valve into the opening provided in the
cab floor.
- Fasten the unit with the screws (4).
- Reconnect the cables of the electrical system.
- Refit the panelling.
- Reconnect the hydraulic hoses.
- Bleed the hydraulic circuit before recommissioning.

Refitting the steering column


- Slide the steering column into the opening provided in the cab floor and stick the gearing into
the steering valve.
- Fasten the steering column with the screws (5) to
the steering valve.
- Fasten the complete unit with the screws (4) in
the cab.
- Reconnect the connectors of the electrical system.
- Refit the panelling.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Control levers

7 - 33

40000300-en

Preparations
- Secure the machine as described under 'Securing the machine'.

The control lever is fastened to the console with a


screw (1) in all four corners of its base.

- Shut off the engine and the ignition.

- Lift the rubber bellows over the screw.

Replacing the control lever

- Loosen the four screws (1).


- Lift the control lever cautiously out of the opening.
- Withdraw the plug.
- Plug the connector into the new control lever.
- Place the control lever into the opening provided.
- Fasten the lever with the four screws in the corners of its base.

Fig. 1

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 34

REPAIR INSTRUCTIONS

WX210 - WX240

Display

40000301-en

Fig. 1

Preparations

Refitting the display unit

- Secure the machine as described under 'Securing the machine'.

- Slide the display base onto the end of the tube


and fasten it with the screws (5).

- Shut off the engine and the ignition.

- Bring the display unit into position over the base


and fasten with the screws (3) leading the cables
through the groove provided in the console.

Removing the display unit


- Remove the six screws (1) in the lateral console
panel.
- Mark the connectors (7) and unplug them.

- Replug the connectors (7).


- Place the panel back onto the lateral console
and fasten it with the screws (1).

- Remove the four screws (3).


- Remove the upper part of display unit (4) from
display base (6) and replace it.
- To remove the base, loosen the screws (5) and
withdraw the base from the tube.

Make sure no cables are getting


caught between the parts when refitting the console panel.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

ESX Box

7 - 35

40000302-en

Preparations
The ESX Box is located on the right under the cab
beside the slewing ring.

- Pull locking lever (1) of the connector forwards


and withdraw connector (2) from the control unit.

- Secure the machine as described under 'Securing the machine'.

- Detach the grounding cable of the ESX Box on


the excavator.

- Shut off the engine and the ignition

Removing the ESX Box

Fig. 1

Fig. 3

- Screw off the baseplate (102).

- Loosen the screws (4) and remove the control


unit.

Refitting the ESX Box


- To refit the ESX Box, perform the above working
steps in reverse order.

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 36

REPAIR INSTRUCTIONS

WX210 - WX240

Load-limit regulator
Preparations
- Secure the machine as described under 'Securing the machine'.
- Shut off the engine and the ignition.

40000303-en

- Withdraw the connector by pulling locking lever


(1) away from the connector and by pulling out
connector (2) upwards from the PCS unit. The
front extension of the connector must be disengaged.

Removing the load-limit regulator

Fig. 1

Fig. 3

- Detach the step (4) behind the cab (Fig. 2) by


loosening and removing the screws (5).

- Loosen the nuts fixing the load-limit regulator


and lift the regulator out of the electronics compartment.

Refitting the load-limit regulator


- To refit the load-limit regulator, perform the above
working steps in reverse order.

Fig. 2

- Remove the cover of the electronics compartment at the rear of the cab.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Removing and installing the battery

Switch off the engine before removing the batteries to prevent


damage to the alternator and regulator or to electronic components.

7 - 37

40000304-en

The two 12-volt batteries are connected in series.


The voltage in the electrical system of the machine
is therefore 24 volts.
Open the flap in front at the right over the batteries.

Set the key-switch of the electrical


system to '0' and withdraw the key.

- Unscrew the battery holders and remove the


cover over the batteries.

Detach and mount the pole terminals in the specified sequence.

- Detach the negative battery terminal.

Non-observance of the correct sequence may result in short-circuiting.

- Remove the bridging cables between the batteries.


- Detach the positive battery terminal.
- Insulate the pole terminals.
- Lift the battery out of the battery box.
Prior to installing the new battery, make the contact surfaces of the battery poles and the terminals
bright.
- Install the new battery.
- Connect the pole terminal to the positive pole of
the battery.
- Refit the bridging cables between the batteries.
- Tighten the clamping screws of the terminals
Never use force when tightening the clamping
screws, however, as this might result in damage.

Fig. 1

- Connect the terminal to the negative pole of the


battery.
Then coat battery poles and terminals with pole
grease or non-acid Vaseline.
Loose or corroded terminals overload the alternator and the regulator.

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 38

REPAIR INSTRUCTIONS

WX210 - WX240

Combined radiator

40000305-en

To remove the combined radiator, it is necessary


to detach the panelling sheets at the battery box to
ensure sufficient room for working. The panelling
sheets must not be removed completely, though. It
is sufficient to loosen and to shift them aside.
To shift the panelling sheets, it is necessary to
remove the cover of the battery box, the battery
itself and the flap of the fan.

Preparations
- Secure the machine as described under 'Securing the machine'.
- Shut off the engine and the ignition.
- Depressurize the hydraulic system.

Fig. 2

Removing the combined radiator


- Remove the above-mentioned components.
see:

battery box
fan flap
battery box panelling sheets
Collect escaping oil in a suitable
recipient and discard without polluting the environment.

- Detach and remove the hosepipes.

Fig. 3

- Loosen the screws (31) fixing the radiator to the


frame.
- Attach the radiator by means of eye-bolts to a
crane and lift it slightly.
- Push the combined radiator slightly forwards to
disengage the connecting pieces.
- Lift the combined radiator out of the frame and
slew it aside.

Refitting the combined radiator

Fig. 1

- Position the combined radiator with the crane


inside the frame and fasten it with the screws
(31) and the washers (33).
- Make sure insulating element (19) is in the correct position.
- Refit all hoses.
- Refill and bleed the hydraulic system.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Battery box

7 - 39

40000353-en

Preparations
- Secure the machine as described under 'Securing the machine'.
- Shut off the engine and the ignition.
- Depressurize the hydraulic system.
Shut off the engine before removing
the batteries to prevent the alternator
and the regulator as well as the electronic modules from being damaged.
Turn the electrical system key-switch
to position '0' and withdraw the key.
Disconnect and reconnect the battery terminals in the described order.
Disconnecting and reconnecting in
the wrong order may result in short
circuits

Fig. 2

Battery box, removing the hood


- Remove the gas-filled springs. To do so, open
the wire clips (6) in the spherical spring heads (5)
and pull them out of the bore.
- Withdraw the spherical spring heads from the
balls.
- Loosen the four screws of the hinges (3) and
remove the hood (1).

Battery box, refitting the hood


- Position the hood over the battery box (1) in such
a way that the four screws of the hinges (3) can
be screwed in.
- Fasten the hood with the four screws.
- Place the spherical heads of the gas-filled
springs on the balls.
- Secure the gas-filled springs with the wire clips.

Fig. 1

Legend
1
2
3
4

Hood
Gas-filled spring
Hinge
Battery

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 40

REPAIR INSTRUCTIONS

WX210 - WX240

Fan door

40000354-en

Preparations
- Secure the machine as described under 'Securing the machine'.
- Shut off the engine and the ignition.

Collect any escaping oil in a suitable


recipient and discard without polluting the environment.

- Depressurize the hydraulic system.

- Attach the fan door to a crane and lift it slightly to


compensate for the weight.

Removing the fan door

- Remove the four screws (11) in the door hinges


(10) and remove the door.

Refitting the fan door


- Position the fan door with the crane in such a
way that it can be fastened with the screws (11)
and the hinge (10) to the superstructure frame.
- Fasten the door with the four screws (11).
- Reconnect the hoses and the connector of the
fan motor.
- Refill and bleed the hydraulic system.

Fig. 1

- Open the fan door (9)


- Mark the hoses (7) connected to fan motor (8).
- Remove the hoses and withdraw the connector
from the fan motor. Close the openings of the fan
motor and of the hoses.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Battery box panelling

7 - 41

40000355-en

Removing the metal panel

Refitting the metal panel

To remove the combined radiator, the panel must


be slided a bit in forward direction. The components fastened to the panel may therefore remain
in place.

- Fasten the metal panel with the screws to the


frame.

Fig. 1

- Loosen the screws holding the panel in place.


- Slide the panel forwards.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 42

REPAIR INSTRUCTIONS

WX210 - WX240

LINK BETWEEN SUPERSTRUCTURE AND UNDERCARRIAGE


COMPONENTS
Removal and refitting of the rotor
Removal and refitting of the slewing gearbox
Removal and refitting of the ball-bearing slewing
ring

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

40000293-en

WX210 - WX240

REPAIR INSTRUCTIONS

Rotor

7 - 43

40000356-en

Preparations
- Park the excavator on a level surface and secure
the undercarriage with chocks under the wheels
to prevent inadvertent movements.
- Depressurize the hydraulic system.

Removing the rotor

- Close all openings of the hoses and of the rotor


with plugs to prevent soiling.
- Withdraw the connector from the electric slip-ring
carrier at the undercarriage.
- Loosen screw (4) which fastens the slip-ring to
the rotor and remove the slip-ring carrier, pulling
the cable with precaution through the rotor.
- Loosen the screws (No. 2) from below and let the
rotor down.

Refitting the rotor


- Lift the rotor (1) from below into the opening of
the undercarriage, tighten the screws (2) with the
washers (3).
- Slide the slip-ring carrier cable through the rotor,
place the slip-ring carrier on the rotor and fasten
it with the screws.
- Reconnect the hydraulic hoses and the connector.
- Bleed the hydraulic system.

Fig. 1

- Detach all hydraulic lines from the rotor (1). Mark


the positions of the hoses for refitting.
Collect any escaping oil in a suitable
recipient and discard without polluting the environment.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 44

REPAIR INSTRUCTIONS

WX210 - WX240

Slewing gearbox
Preparations
To remove the slewing gearbox, it is
necessary to remove the complete
control block beforehand.
For repairs and overhauls, the slewing gearbox
unit should be removed as a whole and dismantled
in the workshop.
Only the slewing brake can be reasonably repaired
or replaced without removing it from the machine.

Removing the slewing gearbox

40000357-en

- Remove the screws (4) and lift the gearbox with


the help of a crane out of the opening.
The slewing gearbox is fixed with
adhesive at the contact surfaces. To
loosen the glued connection, knock
lightly with a hammer against the
flange edge.

Slewing gearbox, fitting


- Clean the contact surfaces of the slewing gearbox and the undercarriage frame thoroughly with
a diluting agent to remove paint and grease before checking it for damage.
The contact surfaces must be metallically bright,
dry and free from grease.
- Apply a 1-mm thick round strip of adhesive
around each hole of the fastening screws.
When applying the adhesive, keep
some distance from the holes to prevent adhesive from getting in contact
with the threads of the screws when
assembling the parts.

Fig. 1

- Park the excavator on a level surface and secure


the undercarriage with chocks under all wheels
to prevent inadvertent movements.
- Lock the superstructure.
- Depressurize the hydraulic system.
- Mark and remove all hydraulic lines, the expansion tank (2) and the speed sensor (3) from the
gearbox (1).
Collect any escaping oil in a suitable
recipient and discard without polluting the environment.
- Close all openings of the hoses and of the gearbox with plugs to prevent soiling.
- Mark the position of the gearbox and fasten it
with a rope through the eyes to a crane (Pos. 5).

Apply the adhesive only when the


gearbox is ready for fitting.
- Attach the gearbox to the lifting device, bring into
mounting position and place on the undercarriage without changing its position.
- Turn in the screws (4) and tighten.
- Tighten the screws crosswise and mark all
screws that have been tightened.
- Tightening torque: MA=250 Nm
- Reconnect all hydraulic lines.
- Fit the speed sensor.
- Reconnect the line to the expansion tank (2) and
fill the gearbox with oil in accordance with the
operating instructions.
- Bleed the hydraulic system.

Dismantling and assembling the slewing


gearbox
See slewing gearbox handbook.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Ball-bearing slewing ring

7 - 45

40000358-en

Fig. 1

Preparations

Moreover needed:

For replacement of the ball-bearing slewing ring, it


is necessary to lift the superstructure off the machine.

- torque wrench capable of applying a tightening


torque of 250 Nm.

For this work, the following auxiliary means are


required:

- spatula / triangular scraper for cleaning of the


contact surfaces,
- detergent,

- two cranes (lifting capacity 20,000 kg each),


traverse as shown in Fig. 3 and lifting belts with a
capacity of 20,000 kg for removal of the superstructure.

- adhesive for glueing of the ball-bearing slewing


ring,

- crane and lifting gear for lifting and handling of


the ball-bearing slewing ring with a capacity of at
least 260 kg.

- new fastening screws for the slewing ring (see


spare-parts list).

- lubricating grease and

- wrench / socket insert, wrench size SW 24.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 46

REPAIR INSTRUCTIONS

Removing the ball-bearing slewing ring

Risk of accident
Some components of the machine
(e.g. counterweight and boom)
have lifting eyes welded onto them.
Never lift the whole machine at these
lifting eyes. They are not designed
for such heavy loads and might
break.
The lifting eyes may only be used
for lifting of the respective component when it is being fitted.

WX210 - WX240

- The toothed inner ring (1) of the slewing ring is


bolted to the undercarriage, whereas the outer
ring (2) is bolted to the superstructure.
- Attach the superstructure to the lifting gear as
shown in Fig. 3. Pull the slings tight without,
however, lifting the superstructure.
- Loosen the screws (3) of the ball-bearing slewing
ring in the superstructure, keeping the spacers
(5) for re-use.
- The superstructure is now no longer attached to
the undercarriage.
- Lift the superstructure carefully until the pinion of
the slewing gear is free. Slew the superstructure
away from the undercarriage.

- Park the excavator on a level surface and secure


the undercarriage with chocks under all wheels
to prevent inadvertent movements.
- Depressurize the hydraulic system.
- Remove the rotor as described before or detach
all hoses and electrical cables between superstructure and rotor.

Fig. 3

- Attach the ball-bearing slewing ring to a lifting


device (Fig. 5). To do so, stick three eye-bolts
through three bores 120 apart and fasten them
with nuts.
- Remove the screws (4) and keep the spacers (6)
for re-use.
- Lift the slewing ring off the undercarriage.

Fig. 2

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 47

Fitting the ball-bearing slewing ring


- Remove the corrosion protection lining when a
new slewing ring is to be installed.
- Clean all surfaces on the the superstructure and
the undercarriage thoroughly. The contact faces
must be metallically bright, dry and free from
grease. Remove any surface irregularities and
burrs.
- Clean the bores in the undercarriage. Clean the
threaded holes in the superstructure carefully,
check the threads and rethread if they are damaged.
- Apply adhesive on the contact surface of the
undercarriage using a paint roller, a hard brush
or a plastic spatula.
Prevent the adhesive from getting
into the bores: adhesive in the
threads leads to higher friction and
thus to wrong tightening torque
results.

Fig. 4

- Attach the new slewing ring to the lifting gear.


- Turn the inner and the outer ring so that the "S"
marking on the outer ring is at 90 degrees to the
direction of travel and that the "S" marking on the
inner ring is located opposite (Fig. 6).
Slewing rings are induction-hardened. The "S"
markings designate the area between the beginning and the end of the hardened part of the race
which, due to hardening constraints, could not be
hardened.
For this reason, the slewing ring is intentionally
installed in such a way that these areas are located outside the zones of main stress.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 48

REPAIR INSTRUCTIONS

- Slew the slewing ring with the crane over the


undercarriage and let it hover above the contact
area without lowering it at this time. Turn in at
least three new screws (4) with spacers (6) as a
guiding aid.
- Let down the slewing ring carefully.
- Detach the lifting gear from the slewing ring.
- Insert the new screws with spacers and tighten
crosswise with a torque wrench.
- Tightening torque MA=250Nm
- Mark the tightened screws.
- Now apply adhesive also on the contact surface
of the superstructure.
- Apply a thick layer of grease on the slwewing
ring toothing until the gaps between the teeth are
filled with grease.

WX210 - WX240

- Refit the rotor.


- Reconnect all hydraulic lines to the rotor.
- Detach the lifting gear from the superstructure.
- Fill and bleed the hydraulic system, put the machine into operation and check all hydraulic lines
at the rotor for leaks and tigthness.
- The adhesive between the slewing ring and the
superstructure and undercarriage increases the
resistance of the bolted joints and seals at the
same time the joint gaps.
- The adhesive hardens under exclusion of air.
The adhesive is fully hardened after about 6
hours. The machine should not be loaded beforehand.

- Slew the superstructure with a crane over the


undercarriage and let it hover over the slewing
ring without, however, lowering it at this time.
- Lower the superstructure further, engaging the
pinion in the toothing.
- Turn in at least three new screws (3) with spacers (5) as a guiding aid.
- Lower the superstructure carefully.
- Insert the remaining new screws with spacers
and tighten crosswise with a torque wrench.
- Tightening torque MA=250Nm
- Mark the tigtened screws.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

UNDERCARRIAGE COMPONENTS

Fig. 1

No.

Quantity

Designation

Weights

Steered axle, floating

650 kg

Rear axle, gearbox

650 kg

Wheels

105 kg

Steps, left side

35 kg

Steps, right side

60 kg

Stabilizers

Levelling blade

260 kg

Cardan shaft

30 kg

Speed sensor

10

Floating-axle cylinder

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 49

40000211-en

7 - 50

REPAIR INSTRUCTIONS

WX210 - WX240

Axles and gearboxes


Instructions for the repair of gearboxes
and axles
Care and cleanliness are important prerequisites
for the proper assembly of a gearbox.
Improperly installed parts can lead to severe gearbox trouble even after a short time.
Gearbox casings must be cleaned with a detergent. If no detergent is available, diesel fuel will do
the job, too.
Damage (e.g. scratches) caused during the work to
machined surfaces must be repaired.
Clean each part before the assembly and check for
damage or wear and replace, if necessary.
Before pressing in shafts, bearings etc., both parts
must be oiled.
Do not use open flames for warming bearings or
seats, but hot plates, ovens or similar appliances.
Parts installed warm must be redriven after cooling
to ensure a perfect fit.

40000359-en

Testing procedures
Running noises
Mechanical gearboxes develop running noises
when in operation. The noises depend on the state
of loading and the gearbox condition. Normal gearbox noise consists of a whole spectrum of frequencies.
The greater part of the noise stems from friction
bearings and meshing gear teeth. This means that
damage of bearings or toothings can be heard as
rumbling, knocking or beating. A simple stethoscope can be used to detect these phenomena
and, in many cases, to determine their cause.

Leaks
Oil losses due to leaks are critical for more than
one reason and must therefore be attended to
immediately. On the one hand, there is always a
loss of oil and on the other the risk of polluting the
environment.
Leaks can occur at sealing faces, partial joints and,
above all, at shaft ends.
Fast detection of leaks is possible when leakdetection sprays are used. The gearbox is filled
with compressed air at low pressure and the spray
is applied on the area to be tested. Leaks are then
visible as air bubbles.
Another method consists in the application of oilabsorbing contrast agents (e.g. Spanish white),
with which even the smallest leaks can be detected.
Gross leaks with the formation of droplets or even
oil puddles on the ground require immediate resealing of the parts concerned, if possible by replacing the sealing rings.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Brake disks, checking the lining thickness

7 - 51

40000281-en

Preparations
The brake disks must be checked in compliance
with the servicing plans.
The required measuring equipment can be ordered
from our spare-parts service under the respective
parts number (see 'special tools' price list).

Checking

- Release the service brake blocking.


- Turn the spindle (5) with the knurled knob down
to the limit stop.
- Note the number of full turns (see mark "0") and
the number of the partial turn.
A full turn corresponds to a spindle travel of
1 mm. A turn by one graduation mark corresponds to 0.1 mm.
For maximum release clearance, see 'checking
the brake disks'.
- If the value found is greater or equal to the reference limit value, the brake disks must be replaced. Contact our Service Dept.
- Screw out the measuring spindle (2) and screw
the plug (1, Fig. 1) back in place.

Fig. 1

The checking procedure must be performed on all


wheels. For checking, proceed as follows:
- Position the machine so that the screw plugs in
the wheel hub are in the position shown (Fig. 1).
- Secure the machine (see: "Securing the machine".
- Screw out the plug (1, Fig. 1).
- Block the service brake, see: "Using the service
brake".
- Screw the measuring device (2, Fig. 2) into the
open bore of the screw plug (fork wrench SW
22).

Fig. 2

- Slacken the lock-nut (4) of the measuring device.


- Screw down the measuring spindle (5) to the
limit stop by turning the knurled knob.
- Set the graduated drum (3) to mark "0" and lock
in this position with lock-nut (4).

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 52

REPAIR INSTRUCTIONS

WX210 - WX240

Bleeding the multiple-disk brake

40000282-en

Preparations
The brake system of this machine consists of two
braking circuits. One circuit for the wheel pairs of
the steered axle and the other circuit for the wheel
pairs of the rigid axle.
If work has been performed on the brake system
during which air might have got into the system
(e.g. replacement of a line), the braking circuit concerned must be bled after the work.

Bleeding
- Secure the machine against inadvertent movements.
- Connect a hose to the minimess port of a multiple-disk brake (Fig. 1).

Fig. 1

- Hold the other end of the hose into a recipient


filled with the same hydraulic oil or fluid as that
used in the machine.
- Start the engine.
- Depress the brake pedal until the hydraulic fluid
flowing out of the minimess hose is bubble-free.
- Repeat the bleeding procedure on the second
multiple-disk brake of this axle.
Bleeding of one braking circuit is then terminated.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 53

7 - 54

REPAIR INSTRUCTIONS

WX210 - WX240

Cardan shaft

40000292-en

Fig. 1

Legend
1

Cardan shaft

16

Screw

16

Nut

Gearbox

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

Removing the cardan shaft

7 - 55

Refitting the cardan shaft

- Park the machine safely.


- Attach the cardan shaft (No. 1) with slings to the
undercarriage frame.
Weight of multiple-disk gearbox: ca. 80 kg
Weight of cardan shaft: ca. 30 kg

Do not attach the slings to hydraulic


hoses, pipes or electric cables.

- Remove the screws (No. 2) and the nuts (No. 3),


lower the cardan shaft and pull inner and outer
halves apart.

Fig. 2

- Make sure during refitting that the markings on


inner and outer shaft are perfectly aligned when
re-assembling the shaft.
- Fix the cardan shaft with slings to the undercarriage and fasten it with the screws and nuts.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 56

REPAIR INSTRUCTIONS

WX210 - WX240

Rigid axle ASP100

40000273-en

Fig. 1

Legend
1

Axial piston motor

Travel gearbox

Wheel-hub

Differential

Pinion

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 57

Removing the rigid axle


- Lift the excavator with the outriggers so that the
wheels of the rigid axle can turn freely.

- Remove the hydraulic and brake lines and close


all openings to prevent the ingress of dirt.

- Secure the steered axle against inadvertent


movements with wedges and by lowering the
levelling blade.
- Prop up the undercarriage safely.
- Shut off the engine and secure the machine as
described under 'Securing the machine'.
- Depressurize the hydraulic system as described
under 'Depressurizing the hydraulic system /
brake system'.
- Remove the the wheels from the rigid axle (Fig.
1)
Fig. 4

Fig. 2

Fig. 5

- Remove the cardan shaft by loosening the


screws
- Prop up the rigid axle using an appropriate device (e.g. lift truck) (Fig. 3).
- Loosen the fastening screws (1, Fig. 4).
- Lower the axle and remove.

Fig. 3

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 58

REPAIR INSTRUCTIONS

WX210 - WX240

ASP100 tightening torques

Fig. 6

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 59

Refitting the rigid axle


- Bring the rigid axle into position under the undercarriage and fasten it with the screws. Lock the
screws with liquid locking agent.
- Install the cardan shaft using new, self-locking
nuts.

Make sure the marker arrows on the


outer and inner part point exactly
towards each each other.
Fig. 7

Tightening torque MA = 60Nm


- Reconnect the hydraulic hoses and the brake
hoses.
- Fill and bleed the hydraulic system and the brake
system.
- Grease the cardan shaft.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 60

REPAIR INSTRUCTIONS

WX210 - WX240

Rigid axle, hydraulic motor and flanges

40000275-en

Fig. 1

Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

1
1
1
1
1
1
1
1
4
1
1
8
1
1
1

Nut
Flange
Cap
Screw
Spring
Ball
Pin
O-ring
Screw
Axial piston motor
O-ring
Screw
Flange
O-ring
Sealing ring

Removal and fitting of hydraulic motor and


flanges
Removal and fitting are described in the axle manual.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

This page left blank intentionally

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 61

7 - 62

REPAIR INSTRUCTIONS

WX210 - WX240

Rigid axle, gearbox housing

40000276-en

Fig. 1

Removing and fitting the gearbox housing


Removal and fitting of the gearbox housing are
described in the axle manual.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 63

Legend
No.

Quantity

Designation

No.

Quantity

Designation

24

Compression spring

29

Bearing

24

Compression spring

30

Coupling wheel

10

Compression spring

31

Retaining ring

Compression spring

32

Bearing

Piston

33

Intermediate ring

34

Retaining ring

Piston seal

35

Bearing

O-ring

36

Ring

Ring

37

Retaining ring

10

Ring

38

Bearing

11

Ring

39

Spur wheel

12

Outer disk

40

Pin

13

Inner disk

41

Spacer

14

Flange

42

Pinion

15

Hollow wheel

43

Screw

16

Thrust piece

44

Washer

17

Retaining ring

45

Piston

18

Ring

46

12

Compression spring

19

11

Outer disk

47

24

Compression spring

20

11

Inner disk

48

24

Compression spring

21

Thrust ring

49

Retaining ring

22

Bushing

50

O-ring

23

Screw

51

O-ring

24

Screw

52

Ring

25

Sun wheel

53

Washer

26

O-ring

54

O-ring

27

O-ring

55

Housing

28

O-ring

56

Housing

Adjusting washer

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

7 - 64

REPAIR INSTRUCTIONS

WX210 - WX240

Ridid axle, differential unit

40000278-en

Fig. 1

Removing and fitting the differential unit


Removal and fitting of the differential unit are described in the axle manual.

Carefully read personal and machine SAFETY INSTRUCTIONS (at the beginning of this manual)

WX210 - WX240

REPAIR INSTRUCTIONS

7 - 65

Legend
No.

Quantity

Designation

No.

Quantity

Designation

15

Screw

14

Differential pin

Conical gear ring

15

Bevel gear

Axle body

16

Bevel gear

Axle body

17

Bevel gear

Bearing

18

Bevel gear

Disk

19

Washer

Bearing

20

Washer

Washer

21

Washer

O-ring

22

Washer

10

12

Screw

23

Planet wheel

11

Housing segment<